Customised solutions for converting mother rolls into smaller rolls

Since the 1970s, CAMPEN Machinery A/S has supplied reliable solutions for converting mother rolls into smaller rolls. With all engineering and manufacturing in Denmark, our focus is on high uptime, outstanding quality, and maximum operator safety. Our robust converting lines are designed to meet your specific format needs. Whether you are reducing roll width, cutting precise roll length, or preparing jumbo rolls for downstream production, our systems combine mechanical reliability with an easy-to-operate interface. Every function—unwinding, precise slitting, controlled rewinding, web guiding, and tension regulation—works together for stable handling, clean edges, and repeatable results, even at high speed. We support your success with onsite trials, full installation, and comprehensive operator training, so you achieve a quick return on your investment.

Customised converting lines for precise roll conversion

Our converting machinery is configured to fit your web material, roll diameter, and required throughput. The shaftless unwinder, with hydraulic loading, ensures safe handling of even the heaviest mother rolls. Integrated web guiding keeps roll edges straight, while the closed-loop tension system protects fragile substrates. Depending on your requirements, select between razor, shear, or crush slitting for the best quality and edge finish. Automatic knife positioning ensures quick changeovers and minimal operator input. Both centre and surface rewinding options are available for optimal roll consistency and build.

Active trim extraction removes edge waste at the source, keeping your work area clear and reducing debris. Turret rewinders reduce downtime and boost overall throughput. All modules are managed by a single PLC control system with recipe memory, trend logging, and alarms. Operators work through a clear HMI, featuring job memory and process data for the most stable results shift after shift.

• Advanced slitting allows for minimal edge waste and lower scrap disposal.
• Controlled tension management helps maintain web quality and reduce roll defects.
• Fast knife adjustments support short runs and frequent format changes.
• Automated rewinding can support continuous production and limit machine stoppages.
• Efficient trim handling creates a tidier, safer workplace.

We integrate complementary systems such as automated roll transport, inspection stations, inline labelling, and automated roll discharge. This approach enables you to manage the full converting process from master roll to final roll on a single platform, ensuring easy control and smooth operation.

Robust design and focus on operator safety

CAMPEN’s converting lines are built for demanding, nonstop production environments. Durable frames and heavy-duty bearings manage large-diameter mother rolls and high inertial loads for smooth, consistent acceleration and deceleration. Our systems help prevent web damage during every phase. Safety is engineered in: CE-compliant guarding, safety interlocks, and integrated safe torque-off are standard. Dust extraction and filtration options are available, and knife housings are designed to minimise particle emission for clean, hygienic operation. Remote support and predictive condition monitoring make it easier to maximise uptime and plan maintenance efficiently.

• Automated roll handling reduces heavy lifting and supports safe working practices.
• Rigid frame structure helps maintain slitting accuracy over the full web width.
• Energy-saving drives and motors cut long-term operational costs.
• Recipe control ensures repeatable, high-quality output across products and operators.
• Modular construction allows easy upgrades and process changes as your needs develop.

From initial floor pick-up to finished roll output, every aspect of handling is covered. Options include automatic core loading, precise core alignment, and powered roll pushers, all designed for secure material handling, quicker cycle times, and reduced errors. Our aim is repeatable, cost-effective converting of mother rolls into smaller rolls, with clear advantages in process stability and workplace safety.

Serving converters in nonwoven and industrial sectors

CAMPEN supplies converters in the nonwoven, tissue, film, packaging, and technical textile industries. Our converting systems are tailored for mother roll downsizing and preparation across a broad range of processes, including airlaid, spunlace, carding, and needlepunch lines. We customise each solution to your product specifications and plant layout. You will receive clear trials, firm performance benchmarks, and documented results throughout the setup and validation phase.

Main operations include width reduction of mother rolls, lengthwise cutting for exact roll sizes, and edge trimming as preparation for the next processing step. We help you get material rolls ready for coating, printing, laminating, or subsequent packaging. Our solution ensures full integration with upstream web processes and downstream finishing equipment—so operators run the whole line from one HMI and one control cabinet.

• Knife systems adapted to nonwoven fibres, tissue rolls, films, and technical materials.
• Stable tension regulation enables smooth handling of light and stretchable products.
• Edge guidance corrects for tracking errors and maintains perfect roll builds.
• Inline quality inspection quickly detects faults and minimises rework.
• Comprehensive data logging for reliable process control and customer documentation.

Our technology enables your operation to deliver consistent, high-quality rolls at defined costs. Whether you process airlaid, spunlace, or advanced fibre blends, we support you with robust machines, stable controls, and expert aftersales service for years to come.

Need help with your converting mother rolls into smaller rolls project? Talk to our engineers or request an assessment today. Learn more at campenmachinery.com/nonwoven or contact us at campenmachinery.com/contact-us.