Winding, unwinding, and rewinding machinery

Sensitive tissue, decor paper, kraft liner, photographic paper or coated paper with different weights, paper can have various characteristics and must be treated therefore correspondingly.

SOMATEC offers for nearly all paper qualities and special papers suitable machine concepts for;

• in-line winding or unwinding and
• for off-line re-reeling or
• slitting and rewinding

Plastic films have very different characteristics and will be used for many applications. The range goes from the classic PVC-film (in soft, semi-rigid and rigid qualities) to PE-film, PU-film, PP-film and at least to ductile and rigid PET and PC-film. Often multi-layer films made by a combination of different films are produced.

Winders and Re-reelers from SOMATEC are designed exactly for the characteristics and demands of the corresponding plastic films. So very thin and soft films as well as thick and rigid films can be wound with different concepts and settings.

Nonwoven or fleece – this is the name for a continuous growing range of products which becomes more and more important at many daily applications or within technical processes. Spun bond, melt blown and airlaid paper; these are only a few products which have to be wound as flat webs during production or converting processes.

The selection and layout of the optimum winding machine for each of these production processes is a specialty of SOMATEC. And this is also valid for further processing during converting to short rolls or during slitting to narrow webs.

Automatic Turret Unwinder UW – E and UW – C Turret unwinder UW 1200 E 

Characteristics

The Automatic Turret Unwinder UW – E and UW -C are equipped with chucks, mounted on indexing disks in a fixed position, to support the unwinding roll. Therefore the roll can be either supported on a winding shaft (UW – E) or shaftless (UW – C). If shaftless unwinding is chosen, length differences up to 250 mm can be compensated. For larger differences, length adaptors will be used. In the case that a winding shaft is used, a pick up from floor level or from a pallet by means of integrated lift-in arms, is available.

Automatic Turret Unwinder UW – S

Characteristics

The Automatic Turret Unwinder UW – S is characterized by its very flexible concept. Besides the support of a high roll weight and a high unwinding speed the unwinder supports reels with a wide width variation without the need of mechanical adaptors or similar. This is achieved by motor driven support arms, which are clamping the reel centered to the machine, able to steplessly compensate a difference in width.

Single- and double-station unwinders

(Double station unwinder with ultrasonic splicing unit)

Single- and double-station unwinders are used mainly in finishing and converting processes of flat webs. Splicing is done either manually at machine stop or – at a double station unwinder – with an automated splicing system. At manual splicing an accumulator is used for a continuous web feeding to the following line. The unwind stations can be either center driven or surface driven, depending on the products requirements. For all these variations SOMATEC has the right solution for your request – please contact us!

Automatic Butt-Splice Units

If it is not allowed or desired to have an overlapped splice during unwinding, a SOMATEC Butt-Splice Unit can be used for an automated butt-splicing at minimum stop time. During splicing the web is either taped on one or both sides and an edge guiding system ensures an edge true splicing result.

Automatic web-tail taping units

In the production line behind the unwinder it might be necessary, due to downstream operations requirements, that the free web tail has to be attached  to the new web. For this requirement, SOMATEC has developed an automatic web-tail taping device, which follows the splicing operation, to attach the free web tail to the new web. An adhesive tape is placed onto a suction bar, which is accelerated in an angle of approx. 270° to the web speed, to precisely attach the web tail to the new web. This operation is possible to a web speed up to 600 m/min (2000 fpm) and an accuracy of plus/minus 40 mm (1.5”).

Automatic Turret Winder ATW – E

The inexpensive variant with winding shafts

The application range of this winder expands from printing lines to the paper production and paper converting industry, but is also perfectly suitable for other tasks, where flat webs have to be wound continuously onto winding shafts. Whether you want to integrate this winder into a new or existing line,it always will perfectly fit. No need to say that this machine concept can also be perfectly adapted to individual requirements. In this case our specialists are eager to develop innovative solutions based on your and their longtime know-how.

The basic machine can be upgraded with many interesting features.

Diverse equipment options for perfect winding results

• Scissor cut or blade cut
• Expansions shaft mode with friction option
• Antistatic equipment
• Driven Lay-on rolls
• Optional contact or gap winding
• Both winding directions possible
• Reel support roller to achieve high roller weights with a small core diameter or with multiple slits

Diverse equipment options for high efficiency:

• Edge trim suction or pull-roll
• Chucks for steel core
• Roll unloading cart with up to 25m driving range
• Optional roll unloading forks
• extern winding shaft extraction
• Automatic roll change system TAC or NTC

Technical Data ATW-E

ATW-C and ATW-S – The shaftless Automatic Turret winder

The comfortable variant of the ATW

Even this machine concept is applicable to all winding tasks, where shaftless winding of flat webs is necessary, the primary application of these winding machines is;

• printing lines respectively
• the paper manufacturing and
• the paper converting industry.

Besides the proven design of the winder AW – C, where the chucks are movable arranged within the side frames, now a new design as AW – S with movable chucks directly on the indexing system is available. So an even higher flexibility for the support of different core lengths is achieved and the winder configuration therefore can be much better accomodated to the production requirements.

Whether the winder will be integrated into a newly designed production line or into a new designed plant, roll quality is always paramount!  Depending on the winder configuration driven rider rolls for optimisation of the winding quality during the indexing process as well as slitting devices for edge trimming can be added. Individual handling devices are also available.

No need to say that each of the machine concepts can also be perfectly adapted to individual requirements. In this case our specialists are eager to develop innovative solutions based on your and their longtime know-how.

For perfect winding results:

• Driven Lay-on rolls
• Optional contact or gap winding
• Both winding directions possible

For high efficiency:

• Shaftless roll mount
• Automatic roll change on cores prepared with adhesive tape up to maximum production speed
• Automatic roll unloading via lifting table or unloading cart
• High flexibility in the realizable roll widths

Technical Data ATW-C and ATW-S

Automatic  turret winder with integrated winding shaft pulling system ATW – I und ATW – IG

Practical and functional. Versatile in use. Already sold over 50 times worldwide.

The turret winder series was mainly developed for use in film and nonwoven production. Thanks to its modular design, it can be ideally adapted to any production situation. This includes the different sizes and the different automatic roll changing systems, as well as slitting systems and handling components that can be integrated into the machine concept.

The ATW – I turret winder is particularly characterized by its integrated winding shaft handling. The winding shafts always remain in the machine, so that the finished roll handling is significantly simplified. In addition, the ATW – IG turret winder is specially designed for the largest roll diameters – up to 2,400 mm – so that it can be used primarily in nonwoven and glass fleece production.

Even special requirements are not a problem – our specialists develop individual solutions for you based on their many years of know-how.

Diverse equipment options for perfect winding results:

• Scissor cut or blade cut
• Expansion shaft mode with friction winding option
• Antistatic equipment
• Driven Lay-on rolls
• Optional contact or gap winding
• Both winding directions possible

For high efficiency:

• Edge trim suction or pull-roll
• Short roll Set-Up
• Chucks for steel core
• Integrated winding shaft pulling system
• Roll unloading cart with up to 25m driving range
• Automatic reel change system TAC or NTC

Technical Data Automatic Turret Winder  ATW-I and ATW-IG

Automatic Surface Winder SW – E

Characteristics

By the compact design and the concentration to the essential functions an economic automatic Surface Winder was created, which works in the basic version only with one drive, but fulfills all actual requirements for a modern and safe winder.

The Surface winder SW – E is characterized by the following advantages:

• Automatic reel change at full production speed onto adhesive prepared cores
• Optimal winding conditions by surface winding from the first to the last layer; thereby no telescoping at multiple web winding during reel change
• Winding tension and contact tension selectable with taper modes
• Compact design, thereby large winding diameters are reachable at smallest machine size

Automatic Surface Winder SW – S

Characteristics

The advantages of this Surface Winder are – besides of the compact design – mainly the possibility of the extension with additional features in order to satisfy most diverse requirements.

A special feature is the support roll, which supports the reel during the whole winding process from below and so eliminates effectively a bending of the winding shaft, especially during multi-web winding. With the additional motor-drive of the support roll a better winding result is achieved.

The Surface winder SW – S is characterized by the following advantages:

• Automatic reel change at full production speed onto adhesive prepared cores
• Optimal winding conditions by surface winding from the first to the last layer; thereby no telescoping at multiple web winding during reel change
• Optional also gap winding mode with additional center drive is possible
• Winding tension and contact tension selectable with taper modes
• Motor-driven support roll for optimum support of the reel
• Winding shaft magazine
• Compact design, thereby large winding diameters are reachable at smallest machine size

Automatic Surface Winder SW – R  “Reelwinder”

Characteristics

The “Reelwinder” is designed for winding of biggest reels – up to 3000 mm (118″) – especially in nonwoven production lines.

The automatic reel change is done at full production speed. By the contact roll design a constant winding in contact winding mode is achived, also during reel change. Hereby the contact pressure is controlled permanently by a two-dimensional pressure control system. The additional center drive of each winding station supports the surface drive and ensures a smooth start of each new reel.

The Surface winder SW – R is characterized by the following advantages:

• Biggest winding diameters are possible
• Automatic reel change at full production speed onto adhesive prepared cores
• Optimal winding conditions by controlled surface winding from the first to the last layer
• Winding tension and contact tension selectable with taper modes
• Winding shaft magazine and automatic winding shaft feeding

Special winders

Please tell us your special request for any winding technique related task, we will develop the corresponding solution and manufacture an tailor made winding machine for you.

• High speed turret winder for polyester film (4-20my; 1.5-8.0 microns)
• Single station winder EAW-1500/2600 E for paper within a printing line, – Reel support with winding shafts up to 2500 mm width – Reel weight max. 3500 kg – Winding speed max. 400 m/min
• Single station winder for plastic films behind a lamination line

Unwind and rewind stations for Re-reeler and Slitter-Rewinder

The following solutions are possible for the unwind and rewind stations of Re-reeler and Slitter-Rewinder:

• Reel support with winding shafts or shaftless via expanding chucking heads
• Hydraulically or motorized operated lift-in or deposit of the reels
• Unwind stand with pneumatic brake or regenerative brake
• Edge guiding or steering system either by sideways movement of the unwind or by a pivoting frame
• Splice table for a safe web splicing after the unwind
• Multiple web winding -depending on the material type -on one common shaft or two friction winding shafts

Additionally the following devices for web and reel handling are available:

• Web thread-in devices
• Reel loading or unloading carts
• Winding shaft handling systems

Web processing equipment for Re-reeler and Slitter-Rewinder

For the web processing and/or inspection the following devices can be used:

• Edge trimming and slitting devices with different cutting principles
• Web inspection units
• Auxiliary winding stations for laminating/de-laminating and for winding of scrap material
• Web pre-treating devices
• Defect detection systems

If a roll change shall or have to be done at machine stop during unwinding or rewinding processes an accumulator ensures the continuous web transport to or from the production line.

For these tasks SOMATEC offers the most different accumulator designs and sizes. The accumulator carriage either will work from bottom to top or vice versa. The comb design enables an easy thread-in of the web during start-up of the line. Depending on the products and on the process requirements capacities from only a few meters up to 200 m (660 ft) are possible.

These are individual function groups, which are arranged and operated relatively independent from the main machine or which will be added later to the main machine.

Mainly these are edge trim winders, which can be mounted either directly at the main machine or will be arranged besides the production line. Also slitting units for scissors cutting, blade cutting or crush cutting as well as handling components as roll unloading carts or shaft extractors are winding components which belongs to this equipment.

Not only a new machine but also modernization and upgrading of existing components can increase output and safety of production of a production line. SOMATEC offers the entire spectrum of service (independently if it is a SOMATEC made machine or if it is another manufacturer’s product) like:

• Extensive consultations about technical and commercial feasibility of a modernization task
• Detailed examination of the existing situation on site
• Technical preparation by our designers
• Manufacturing and pre-assembly of all relevant parts for the modernization
• Mechanical and electrical integration into the existing line by our experienced service personnel
• Installation and start-up of the modernized machine

Please contact us, we are pleased to support you at the modernization of your existing machines or lines.