Web Converting | Winding & Tension Control

From Empty Core to Full Roll. Same Tension. Every Millimeter.

Drives that calculate diameter in real time—so your material doesn't telescope or star‑burst.

High‑speed slitters transform master rolls into finished slit coils at speeds exceeding 600 m/min. The rewinding process presents a fundamental control challenge: as roll diameter builds from empty core to finished coil, the relationship between motor torque and web tension changes continuously. Fixed‑parameter drives produce telescoped rolls, crushed cores, or stretched materials that fail downstream…

What Goes Wrong Between Core and Finished Roll

- We shold know the pain point! -

Telescoping at small diameters

At empty core, insufficient torque produces loose winding layers. Centrifugal force at high speed shifts these layers axially—producing telescoped rolls that are unsellable.

Star‑burst crushed cores

At large diameters, constant torque translates to crushing radial pressure. Inner layers buckle, cores collapse, and the entire slit roll becomes scrap.

Material stretch and gauge variation

Extensible films and nonwovens permanently deform under excessive tension. Gauge thins, yield length shrinks, and downstream converting processes fail.

Inertia mismatch during acceleration

Heavy finished rolls present massive inertia. Without inertia compensation, acceleration ramps produce severe tension spikes that snap webs or stall drives.

Wound Perfectly. Every Time.

- How We Solve It? -

We solve the 10:1 diameter challenge through real‑time diameter calculation that tracks buildup from line speed and motor RPM—no external sensors required for most applications. Our integrated taper tension algorithm automatically reduces tension setpoint as roll diameter increases, following user‑programmable linear, hyperbolic, or custom curves that prevent both loose starts and crushed finishes. Closed‑loop feedback from dancer position sensors or load cells provides sub‑millisecond tension correction, while inertia compensation automatically boosts torque during acceleration and trims it during deceleration to maintain constant web stress. For center‑surface and duplex winding configurations, our drives support master‑slave load sharing with torque‑follower modes that prevent motor fighting. Built‑in static friction compensation ensures smooth breakaway from zero speed without tension spikes.