Process control in in-line converting for technical textiles

Since the 1970s, we have helped nonwoven and technical textile producers run stable and efficient production lines. Our focus is clear: robust machinery with reliable process control in in-line converting. We deliver solutions that ensure consistent roll quality, safe operation and predictable costs. Our engineers combine decades of experience with modern technologies to manage sensitive fabrics and demanding roll-to-roll converting environments. We bring proven hardware and intuitive process control in in-line converting to help your production stay within specifications, shift after shift. We work closely with your team and adapt every solution to your materials, performance targets and factory standards.

Why efficiency and quality depend on precise converting management

Effective process control in in-line converting is essential to maintain product quality at any line speed. This approach reduces variation, protects delicate webs and provides repeatable roll build-up. In nonwoven converting, even small changes in tension or slitting knife position can cause defects or waste. Our process control in in-line converting keeps settings stable, monitors deviations and reacts quickly. As a result, you benefit from improved uptime, fewer line stops and reliable production data.

We integrate process control in in-line converting across both upstream and downstream equipment. Winding, slitting and rewinding are synchronised with extruders, bonders and coaters. Drives, sensors and actuators form one reliable system. Operators use a single interface for recipes, set-up and alarms. Changeovers become faster and safer.

Closed-loop tension control supports stable fabric flow, helping to avoid wrinkles, neck-in and web breaks.
Adaptive web guiding minimises edge wander and reduces trim waste.
Recipe control enables consistent roll dimensions and hardness grades.
Automatic roll change and splicing improve effective line utilisation.
Integrated inspection and data logging support quality control and reporting.

We tailor our process control in in-line converting to each fabric type and roll format. Whether you run spunlace, meltblown or multilayer laminates, we apply the right sensors and control strategies. Our approach supports both in-line converting systems and off-line winding cells.

Main features: controls that secure uptime and optimise output

Our process control in in-line converting uses industrial PLCs, safety PLCs and drive-based control. We ensure open interfaces for factory MES and ERP systems. Our designs comply with EU safety standards and your internal procedures. The HMI is straightforward and easy to operate, with step-by-step set-up and diagnostics.

Core functions driving consistent results

Load-cell and dancer-based tension loops provide stable tension, which helps protect sensitive fabrics and improves slit edge quality.
Web guiding with camera or ultrasonic sensors maintains edge position, reducing trim and preventing misalignment.
Slitting control featuring motorised knife positioning speeds up changeovers and increases capacity.
Winder control with taper tension and torque sharing forms uniform rolls, supporting efficient downstream unwinding.
Zero-speed or flying splice reduces roll change times, supporting higher average line speed.
Integrated inspection and defect mapping direct targeted sorting and support high final quality.
Alarm management and predictive maintenance tools reveal root causes and help prevent unplanned stops.
Energy-optimised drive control reduces power peaks, helping to lower operating costs.

Every function is designed to support key converting KPIs such as product quality, production efficiency and operator safety. We supply recipe libraries adapted to various fabric types, line speeds and roll dimensions. Operators can recall proven settings instantly. Clear data trends and reports simplify audits and documentation. Our remote support keeps your process control in in-line converting stable and reliable.

Flexible technology: supporting both in-line and off-line needs

Whether you run product directly in-line or require the flexibility of off-line converting, our process control in in-line converting supports both options. In-line converting minimises handling and speeds up delivery. Off-line slitting and rewinding offer freedom for smaller orders and variable roll formats. We guide you to the process control in in-line converting or off-line solution that fits your volume, product range and staffing.

Modular design can be scaled from basic off-line winding to complete in-line converting cells.
Shared HMI and recipes reduce training needs and ease operation across formats.
Wide tension ranges and adjustable web paths adapt to both heavy technical textiles and lightweight nonwovens.
Integrated roll handling and safety functions reduce manual lifting and increase workplace safety.
Open protocols connect to broader plant systems, supporting traceability and efficient planning.

For decades, we have supplied winding, slitting and rewinding lines to leading nonwoven producers. Our machines are reliable, robust and easy to operate. We design for cleanability and quick access for roll or knife changes. We also retrofit process control in in-line converting to existing lines, extending service life and improving stability.

Project evaluation and next steps for improved process control

Let us assess your current lines and performance targets. Our team reviews your web paths, sensor layout, drives and control schemes. We then propose practical steps to upgrade your process control in in-line converting or off-line cells. You receive a realistic action plan, expected ROI and ongoing support from our service team. Contact us to discuss your materials, roll sizes and capacity needs. We are ready to design, deliver and support a robust process control in in-line converting solution for your facility.

Need help with your process control in in-line converting project? Talk to our engineers or request an assessment today. Learn more at campenmachinery.com/nonwoven or contact us at campenmachinery.com/contact-us.