Web tension control system solutions for reliable production

Since the 1970s, CAMPEN Machinery A/S has supported manufacturers in handling challenging webs with control and reliability. Every web tension control system is configured for your material, production process, and safety standards. Our engineering teams unite robust mechanics with real-world experience for consistent and reliable results. By focusing on stable web transport, accurate web tension control, and improved roll quality, we help you achieve efficiency, reduce downtime, and safeguard operator safety. You gain quality equipment, clear documentation, and responsive support—keeping your line productive and secure.

Delivering accuracy and stability for demanding web materials

Our web tension control systems are developed for elastic, rubber, and sensitive webs, addressing the unique needs of each production line. Each solution matches your material properties, process speeds, and safety regulations. Using load cell-based feedback and precise control of motors or brakes, our systems maintain web tension at all production speeds. This approach prevents stretching, enables accurate slitting, and preserves roll quality, even as diameter and speed change.

At the unwind station, controlled unwinding prevents inertia peaks and overstretching. Advanced web guiding modules maintain precise edge position, correcting for roll irregularities. On finishing and winding, torque and taper control guarantee tight and uniform rolls with smooth roll edges. Our operator interfaces are easy to operate and offer clear set-points, trend displays, and alarms for error reduction and simplified changeovers.

• Consistent tension reduces wrinkles, telescoping, and bagging in sensitive materials.
• Accurate web tension optimisation improves slitting and winding, minimising waste.
• Controlled acceleration protects elastic and rubber webs from overstress and snapping.
• Load cell feedback supports real-time process monitoring and quality control.
• Full closed-loop systems deliver stable results as diameter or speed changes.
• Simple operation reduces training time and operator errors.

We offer add-ons for special applications—such as low-adhesion rollers for tacky or coated webs, anti-static units, and custom nip designs. For rubber and high-elasticity webs, we use soft contact points, advanced drive technology, and tuned PID regulation. This ensures robust and repeatable web handling, protecting your material value and supporting high uptime.

Specialised solutions for nonwovens and technical web handling

CAMPEN delivers web tension control systems for nonwovens, laminates, coated fabrics, and elastic production. Our experience covers filtration media, hygiene nonwovens, and challenging rubber web applications. We understand how porosity, surface tack, elastic properties, and coating weight can affect your operations.

Our tension control is easily integrated across unwinds, accumulators, slitters, coaters, laminators, and winders. We tailor every system as a complete process solution—optimising mechanics, sensor position, and drive settings for your needs. During commissioning, we run material trials and train operators for fast and stable production ramp-up.

• Custom design supports tight tolerance requirements in technical fabrics.
• Edge guiding and web spreaders minimise web wander and creasing risks.
• System layouts (dancer or load cell-based) are adapted to your line.
• Modular frames and electronics allow easy upgrades or speed increases.
• Recipe management supports quick product changeovers and reliable output.
• Wide industry references demonstrate long-term performance and quality.

We work flexibly with your production, maintenance, and technical teams to develop clear tension zones and web paths. Pre-delivery simulations and test runs with sample materials help verify operating parameters. Our project management includes clear documentation and schedule control, ensuring a smooth installation and production start.

Focus on reliability, operator safety, and lifecycle service

Our web tension control system platform is open, reliable, and easy to maintain. We offer integration with leading PLCs and drive systems, allowing connection with your MES or SCADA for process data and traceability. Our design approach ensures clear diagnostics, easy-to-use HMIs, and complete alarm handling. All systems include CE-marked safety, such as e-stops and drive safety functions. Service access is planned for safe and quick maintenance to reduce downtime.

Energy efficiency is standard. We install energy-efficient motors and regenerative drives to recover energy during braking. Standby modes help to reduce power when the line is idle. Condition monitoring for bearings, belts, and load cells alerts you to potential problems before they can cause unplanned stops. Remote support is available for troubleshooting and fast production recovery.

• Open interfaces make future expansions and upgrades straightforward.
• User-friendly controls lower the risk of operator mistakes and scrap.
• Integrated safety protects employees while allowing practical machine access.
• Automated data collection supports audits and continuous improvement.
• Retrofit options extend the life of existing production assets.
• Spares and training are available for stable total cost of ownership.

For new projects and retrofits, we customise your web tension control system to match your production targets. We deliver FAT and SAT, on-site commissioning, and clear documentation for maintenance. After installation, our service teams support system optimisation, on-site audits, and upgrades as your materials or business requirements change.

Discuss your tension control project with our experts

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