The customer’s request

The customer needed to replace an existing installation that limited production flexibility and created significant constraints for operators. As a felt material converter applying a hotmelt adhesive film and a protective paper, they wanted a reliable, repeatable and flexible tool for the production of logs from Jumbo rolls, with several key expectations:

• Replace an obsolete machine with reliable and long-lasting equipment
• Manage Jumbo roll unwinding with precise tension control
• Offer great production flexibility (single or multiple logs)
• Improve operator ergonomics and safety

Overall, the customer needed a well-controlled converting process capable of managing Jumbo roll unwinding with precise tension control, while maintaining a high level of productivity and process repeatability.

The CNM response

CNM Process integrated a Pro Lam 1600 machine, configured for length winding, slitting and longitudinal cutting, replacing the old installation. The solution was built around three main components:

• A Jumbo unwinder accepting rolls up to 1400mm in diameter and 400kg, with precise tension control from the line entry and a reduction of roll changeovers
• An automatic material edge alignment system, specifically developed for irregular edges, guaranteeing a constant reference edge and optimal material usage, with continuous and progressive positioning and no pumping effect
• A splicing table with automatic presser, allowing roll-to-roll joining without dismantling or modifying the material path, ensuring process continuity without prolonged stoppages
• A specific calender equipped with a chrome roller heating up to 250°C, ensuring controlled and repeatable application of the hotmelt adhesive film onto the felt
• Adhesive application, slitting and longitudinal cutting combined into a single integrated converting line

Overall, the solution delivers a fully integrated felt converting line, combining unwinding, alignment, adhesive lamination, slitting and rewinding into logs, with optimised ergonomics for the operator throughout the process.

The manufacturing process

The Pro Lam 1600 processes felt material through cutting and heat lamination, with several key strengths:

• A line speed of 60m/min guaranteeing high productivity while ensuring precise tension control and process quality
• Acceptance of Jumbo rolls up to 1400mm in diameter, limiting changeovers and increasing production autonomy
• Production changeovers carried out in under 3 minutes by a two-operator team, reducing line downtime

The advantages of our machine

The Pro Lam 1600 solution offers optimal tension and speed management of the material, while preserving the integrity of the most fragile materials. The vision and AI model alignment, specifically developed for irregular edges, eliminates the risks of drift and material waste. The automatic splicing table ensures process continuity without prolonged stoppages, and the calender with heated chrome roller up to 250°C guarantees controlled and repeatable adhesive application. The simplified roll loading and automatic end-of-roll management allow the operator to focus on essential tasks.