Reliable solutions for web break prevention in nonwoven processes

For decades, CAMPEN Machinery A/S has delivered reliable, robust nonwoven technology to optimise production uptime and safeguard material quality. Our focus on web break prevention delivers proven results for sensitive nonwoven handling, particularly in the critical zone before the winder. Through precise engineering and straightforward operator interfaces, we help reduce tension spikes, stabilise accumulation, and ensure clean roll changes. We work closely with you to analyse your production data and develop turnkey solutions for your specific nonwoven processes and product types.

Improve process stability with low-tension web handling

Web break prevention is a core requirement in modern nonwoven production, especially for lightweight materials like meltblown, spunbond, and wetlaid webs. Our solutions minimise the risk of tension spikes and accidental tears. The belt accumulator and web accumulator systems ensure smooth, tension-free splicing and roll changeovers.

• Continuous low-tension transport of sensitive nonwovens, preventing edge splits and fibre damage
• Stable, tension-free accumulation zone that buffers variations during changeovers
• Precise synchronisation with the winder, reducing stop–start shocks
• Accommodates rapid product changeovers without complex retooling
• Operator safety features and easy access for maintenance

Such technology supports reliable web handling from thread-up to full-speed operation. It also supports a wide range of nonwoven weights and web structures, ensuring trouble-free roll-to-roll handling and reducing costly production stops. Integrated sensors and drive controls work together to maintain optimal path stability.

Technical solutions designed for sensitive nonwoven web

Key features supporting effective web break prevention

• Continuous belt surface prevents point loading and helps minimise start-stop tension surges
• Closed-loop tension control maintains steady, low strain on lightweight nonwoven materials
• Adaptive accumulation buffers allow safe roll build-up and smooth switchover
• Soft-start drive systems reduce mechanical shocks and operational noise
• Anti-static options available to control static on meltblown and lightweight spunbond webs
• Clean, hygienic design for easy maintenance and compliance with production standards
• Compact layout fits seamlessly into existing production lines

Each web accumulator is tailored to your specifications, including belt materials, edge guidance, web spreading, and defect monitoring. Simulation and accumulator sizing ensure your buffer capacity matches your speed, basis weight, and roll change schedule. Operators benefit from intuitive HMI displays and rapid alarms for any developing issue.

Retrofitting a CAMPEN web accumulator is straightforward, with modular kits, brackets, and drives that integrate easily into existing assets. Our focus is always consistent process performance, robust web break prevention, and minimal disruption to your ongoing production.

Experience, engineering and support for nonwoven lines

Our decades of experience in nonwoven machinery and web handling systems are your assurance of a reliable solution. We work with converters and product development teams to solve the challenges of web break prevention and stable accumulation across a range of substrates.

• Application engineering aligns your process and product needs with suitable web accumulator designs
• System testing verifies tension and speed profile before shipment
• On-site commissioning ensures safe setup and detailed operator training
• Lifecycle support, including spare parts, audits, and upgrades to maintain performance
• Modern open controls link with your MES and quality management systems

Our approach delivers long-term uptime, simple maintenance, and process safety. Wear components can be changed rapidly. Integrated diagnostics make root-cause analysis straightforward. Solutions include energy-efficient drives to lower operational costs, and standby optimisation for reduced power use.

Move forward with proven web break prevention technology

Choosing the right web break prevention system helps you avoid unplanned stops and improve product consistency. Our specialised accumulator solutions are trusted by nonwoven producers worldwide for sensitive, lightweight, and technical webs. Through process knowledge and engineering expertise, we ensure your line meets your quality and productivity targets.

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