The Challenge
Increasing Throughput to Meet Growing Product Demand
The customer faced a production bottleneck on their solid fiber insulation line, limiting their ability to meet increasing structural sheathing demand. Their goals included:
- Enhancing system performance across aging web handling equipment
- Expanding capacity without full system replacement
- Improving tension control and slitting accuracy
- Modernizing drive systems, PLC controls, and operator interfaces
MWES was chosen for its deep expertise in web handling and line automation retrofits, enabling a scalable and reliable solution.
The Solution
Comprehensive Line Upgrades for Web Handling and Control System Expansion
MWES delivered a full scope of mechanical and controls upgrades to improve performance and throughput across the customer’s insulation line. Key enhancements included:
- Pneumatic brake upgrades with idler rolls on ten existing unwinds for closed-loop tension control
- New infeed and web guide stations across five web systems with steel support frameworks
- New slitter and cutter with mechanical drive train and dual rotary knife holder system
- Automated sheeting and stacking with reject/cull system, pallet dispenser, and semi-auto pusher
- Fully integrated variable-speed drive and Allen-Bradley PLC control system
- Upgraded operator HMI stations and new drive/control system enclosures
- Safety upgrades and guarding in compliance with current standards
This upgrade package modernized operations and enabled reliable, high-volume production.
The Results
Increased Throughput and Production Reliability for Insulation Manufacturing
The line enhancements enabled higher speed, better control, and more reliable operation across the production line:
- Expanded production capacity to meet surging product demand
- Improved web tension control and material accuracy
- Reduced downtime with modern HMI and PLC interfaces
- Safer, code-compliant equipment guarding and ergonomics
MWES’s upgrades delivered a cost-effective capacity expansion while extending the life of existing assets and improving system performance.
