The Challenge
Coordinating Multiple Web Processes into One Continuous System
The customer required a single system that could take an incoming extruded web and process it through several critical steps while maintaining consistent web handling and tension control.
Key challenges included:
• Managing web tension across multiple process zones
• Ensuring precise alignment through coating and laminating stages
• Applying adhesive and silicone coatings with repeatability
• Integrating liner lamination without disrupting web stability
• Supporting continuous operation with rewind and splice capability
With multiple coating and treatment processes in sequence, even small variations in tension or tracking could impact final product quality.
The Solution
Modular Roll-to-Roll System with Integrated Coating and Web Control
MWES engineered a multi-section web handling and converting line designed to maintain stability and control from unwind through rewind.
Web Cooling, Accumulation, and Rewind
Chill rolls reduce web temperature prior to coating processes, while an accumulator maintains tension during splice events. A turret rewind system supports continuous operation with automated roll changeover and tension-controlled winding.
Liner Unwind and Lamination
A cantilevered unwind introduces the release liner, with guided positioning to maintain alignment into the laminating nip. Closed-loop tension control ensures consistent liner application to the adhesive layer.
Surface Treatment and Adhesive Coating
A corona treater prepares the web surface, followed by a slot die coating system that applies pressure-sensitive adhesive. Positioning systems maintain coating accuracy across multiple web widths.
Silicone Coating and UV Cure
A three-roll offset gravure coater applies a silicone layer to the top side of the web. The coating is cured using a UV system, completing the functional structure required for tape production.
Coordinated Drive and Control System
A multi-axis AC drive system with load cell feedback maintains tension and speed synchronization across all sections. An integrated PLC and HMI provide real-time monitoring and control of web handling, coating, and rewind functions.
The Results
Stable Web Handling and Integrated Converting in One System
The integrated tape line provided the customer with:
• Controlled roll-to-roll processing from extrusion through rewind
• Reliable runs at speeds of 60 ft per minute with smooth web control
• Consistent web tension and alignment across multiple process zones
• Integrated adhesive coating, silicone coating, and lamination
• Continuous operation supported by accumulator and turret rewind
• Structured testing, training, and startup support
By consolidating multiple processing steps into one engineered system, MWES delivered a solution designed to support consistent coating performance, stable web handling, and reliable production flow.
