Reliable web tension measurement and control systems for sensitive materials

Since the 1970s, CAMPEN Machinery A/S has supported manufacturers in achieving reliable web handling. We design and deliver robust web tension measurement and control systems for challenging processes. Our engineers combine technical expertise with hands-on experience. We listen, clarify your goals, and provide a solution that is easy to operate. With CAMPEN, you achieve stable web transport, repeatable quality, and safe operation. From pilot lines to high-speed production, we offer clear advice and thorough service. We understand elastic and sensitive materials, as well as the risks of stretch, curl, and telescoping. Using our systems, slitting, unwinding, and rewinding remain consistent, shift after shift.

Precision systems for elastic, rubber, and sensitive web materials

We engineer complete tension control systems tailored for rubber, elastic, and specialty webs. Each system uses precise web tension measurement, guided transport, and reliable torque control. Every solution is adapted to your line layout, material, and safety requirements. Our focus is on high uptime, clean operation, and consistent roll quality.

Key components include:

• Load cells on critical rollers for accurate web tension measurement and reduced waste
• Closed-loop motor control, supporting stable handling of elastic or stretchable webs
• Optimised unwinding and rewinding stations for robust roll building without telescoping
• Edge guiding to keep the web aligned and improve slit accuracy
• Dancer and nip systems designed for tacky, delicate, or laminated materials
• Recipe management for safe, efficient product changeovers

We offer stand-alone web tension measurement devices as well as complete roll-to-roll lines. All equipment features robust construction and streamlined maintenance access. Operators benefit from intuitive HMIs and reliable alarm handling. Integration with PLC and plant safety systems is standard.

Proven control and measurement for demanding production

Effective web tension measurement begins with optimal placement of load cells on select idler rollers. Our systems capture true web forces while reducing noise and error. Fast-reacting controls help maintain setpoint tension during speed ramps, splices, and emergency stops. If extra buffering is required, dancer arms are used alongside load cells. This approach supports sensitive materials at high or variable speeds.

Drive control zones use torque motors, brakes, and nips to stabilise each material segment. Each zone upholds its own web tension measurement setpoint, limits, and tolerances. Automatic adjustments account for roll diameter, friction, and material properties. Edge guiding systems keep the web on track without unnecessary tension. For slitting operations, steady alignment reduces web flutter and edge defects.

• Closed-loop motor control ensures accurate web tension through acceleration, deceleration, and indexing
• Filtering strategies limit oscillations to enhance product safety and quality
• Diameter calculators and ultrasonic sensors help prevent over-tension on small cores
• Energy-efficient modes save power during pauses or slow operation
• Data logging supports process documentation and improvement efforts

Operators track setpoints, trends, and KPIs via user-friendly HMIs. Recipes can be selected for different products, ensuring correct web tension measurement parameters every time. Remote diagnostics and support reduce downtime and troubleshooting. All solutions comply with EU safety standards and, where required, support hygienic processing.

Decades of experience in supporting roll quality and operational stability

Our history with nonwovens and specialty web handling systems drives our focus on reliable, easy-to-operate solutions. We test and verify each web tension measurement and control system before delivery, and provide on-site commissioning to ensure a smooth start-up. Comprehensive training, documentation, and spare part support are always included.

CAMPEN understands the technical challenges of handling rubber, elastic, and fragile webs. Our engineering team supports both pilot trials and full-scale production upgrades. Ongoing service and preventive maintenance help you sustain compliance and minimise scrap over time.

• Deep process knowledge ensures correct sensor, roller, and drive selection for your material
• Modular designs allow for simple upgrades and maintenance with minimal disruption
• Preventive service keeps web tension measurement in-spec and reliable
• Retrofits are available to extend the life of your current line and reduce total cost of ownership
• Lifecycle support offers planning tools for risk management and production increases

We tailor all solutions to your targets for yield, OEE, and workplace safety. You benefit from consistent web tension measurement, fewer stoppages, and improved roll quality. To discover more about our approach for nonwovens, visit our dedicated solutions page or explore reference cases from satisfied customers.

Speak with CAMPEN’s web tension experts

Tell us about your process, and we will suggest a practical, robust solution. Please provide web width, thickness, elasticity, coatings, desired web tension measurement range (N or N/m), line speed, core dimensions, and maximum roll diameter. We design reliable systems tailored to your available space and production targets. Contact CAMPEN to discuss testing, upgrades, or a complete new line. Our team is ready to help you achieve stable, high-quality results.

Need help with your web tension measurement project? Talk to our engineers or request an assessment today. Learn more at campenmachinery.com/nonwoven or contact us at campenmachinery.com/contact-us.