Methods and apparatus for applying a tab nested zero waste to moving web

A method of fixing lugs (12) to a side frame (10), the method comprising: providing first and second bands supply lugs (16); cutting the first side lugs supply to provide a nested pattern of first and second ears left (12A, 12B), each of the first and second ears left parallel edges of different lengths, orienting the first left lugs in a correct orientation in which the shorter parallel edges of the tabs are oriented in the first direction and orienting the second ears left in a reverse orientation with respect to the correct orientation so that the shorter parallel edges of the second ears left are oriented a second direction opposite the first direction; cut the second band lugs supply to provide a nested pattern of first and second ears right (12A, 12B), each of the first and second ears straight parallel edges of different lengths, orienting the second ears upright in a correct orientation in which the shorter parallel edges of the lugs are oriented towards a third direction and orienting the first lugs right in a reverse orientation with respect to the correct orientation so that the shorter parallel edges of the first lugs rights are oriented a fourth direction opposite the third direction; retaining by vacuum the first and second ears left and right first and second ears; reorienting second ears left in the right left direction using a set of turner lugs expands to a step large enough so that the lugs nest and not leave space for rotation of any other lug; reorienting the first right lugs in the correct orientation using a right rotator assembly lugs expands to a step large enough so that the lugs nest and not leave space for rotation of any other lug; coupling the first left and first right lugs lugs on a side feed chassis to create a first set of chassis and lug; coupling the second ears left and second ears right on the side chassis power to create a second set of chassis and lug, such that for each pair of first left lugs and right in said first frame assembly and lug and each pair of second right and left lugs on said frame assembly and lug, one of the two lugs is rotated 180 °.