The Challenge
Turning Raw Substrate into Finished Pallet-Ready Rolls Ergonomically & Efficiently
The customer needed a continuous-production system that could:
- Process high volumes of adhesive laminated rolls while minimizing labor strain
- Handle heavy rolls and reduce ergonomic risk for operators
- Apply precise web tension, guiding, and substrate layering at full line speed
- Automate finished roll removal, case packaging, pallet stacking, wrapping, and labeling
They selected MWES to design a turnkey solution combining web laminating, roll handling, and robotic packaging to improve throughput and safety.
The Solution
Modular High-Speed Laminating Line with Robotic Palletizing & Packaging
MWES delivered a comprehensive integrated system featuring:
- KTI automatic unwind and rewind units designed for line speeds up to 300 FPM, with mid-line splicing for continuous operation
- Custom-served Davis‑Standard extruder die and die plate changer to handle multiple roll widths and adhesive patterns
- Fanuc robot equipped with pneumatic/vacuum EOAT to unload rolls from rewind and load into shipping cartons
- Automated pallet dispenser, custom stacking logic, stretch wrapping, and robotic labeling station
- Wonderware-based HMI and data-collection platform supporting recipe management, runtime/downtime analysis, and product tracking
This integrated system combines web handling, coating, packaging, and data analytics into a single seamless workflow—from extrusion to palletized roll packaging.
The Results
Consistent High-Speed Operation with Reduced Labor and Full Analytics Visibility
The turnkey system delivered measurable performance gains:
- Palletizes up to 150 finished boxes per hour automatically
- Auto case erector capabilities up to 5 boxes per minute during packaging
- Stretch wrapping and labeling fully automated, minimizing manual touchpoints
- Data-driven recipe control and trending of machine usage, material types, and product tracking
By fully automating from lamination to pallet load-out, MWES helped the customer streamline production, improve safety and ergonomics, and gain operational visibility across the full line.
