Web tension control for elastic materials

We deliver robust and reliable web tension control for elastic materials. With stable tension regulation, you can maintain product quality and maximise line uptime across every process from unwind to rewind. Our technical expertise in winding, web guiding, and drive systems helps ensure your production runs smoothly, with process safety and operator-friendly controls as standard. Each solution is tailored for your material type, line specifications, and automation needs.

Stable tension regulation for elastic and sensitive webs

Elastic webs—such as rubber sheets, stretch films, technical textiles, and coated nonwovens—require precise, responsive tension control. Even minor tension fluctuations can cause stretching, wrinkling or edge defects. Our systems use load cell-based feedback to instantly adapt torque and speed, preventing slack or excess stretch and ensuring web handling remains reliable at high or low speeds.

• Reduced material deformation: Accurate tension control prevents stretching and preserves precise dimensions even on soft, extensible materials.
• Waste reduction: Consistent tension minimises web breaks and cutting errors, especially during speed changes or stops.
• Improved slitting and rewinding: Steady web forces result in clean edges and defect-free rolls, supporting downstream lamination or packaging.
• Operator-friendly controls: HMIs and automatic recipe selection make set-up and changeovers safe and straightforward.
• Adaptation to product variance: Real-time adjustment compensates for thickness or property changes in elastic webs.

Technical approach to controlling tension in elastic materials

Our web tension control for elastic materials is engineered for process stability. We specify load cells with the right force range for your product, and select dancer rollers or accumulators as needed for gentle tensioning. Each solution includes closed-loop motor control for precise torque delivery during acceleration and deceleration. Roller coatings and wrap geometry are customised to avoid slip or marking, protecting the integrity of even highly sensitive or tacky webs.

• Adaptive process control: Algorithms automatically adjust for creep, tack, and thickness changes, keeping your web stable and aligned.
• Edge and web guiding integration: Ultrasonic or optical sensors, combined with automated steering, support accurate lateral positioning.
• Multilane web handling: Independent tension control across lanes ensures uniform roll quality in slitting or laminating lines.
• Advanced safety features: All systems include guarding and interlocks for operator protection and quick access during line stops or splicing.
• Flexible system design: Retrofit modules and new equipment integrate seamlessly with existing drives, PLCs, and data networks.

Integration and production support

Seasoned in web handling, CAMPEN delivers both stand-alone tension control upgrades and complete modules with unwinding, slitting, and rewinding functions. Every web tension control for elastic materials package can interface with your automation, supporting remote diagnostics, OPC UA data communication, and production tracking. Operator interfaces are clear and robust, with recipe libraries and alarm management. We focus on solutions that improve your uptime and build worker confidence in daily operation.

• Efficient commissioning: Pre-tested, documented controls minimise installation time and simplify training.
• Long-term reliability: Consistent, robust performance with ongoing calibration, support, and spare part services.
• Process transparency: Logged data and real-time diagnostics simplify problem-solving and continuous improvement.

Key applications for elastic web process control

• Manufacturing and converting of rubber, TPE, and stretch film webs for gaskets, hygiene articles, and insulation.
• Slitting and rewinding of nonwovens, tapes, and coatings where stress-free transport is critical for product quality.
• Handling of tacky or adhesive surfaces that require gentle, slip-free motion during unwinding, web guiding, or lamination.

Expert consultation for your production line

Every process is unique. Let us know your web materials, typical widths, line speeds, and any concerns with tension or product handling. Our engineers will review your specifications and recommend the most reliable web tension control for elastic materials setup—fitting seamlessly with your equipment and supporting robust, easy operation. With tailored upgrades, retrofits, or new installations, we help reduce waste, protect product quality, and streamline operation for long-term success.

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