Converting Machine Control and Optimization
Increase Converting Machine Speed and Consistency Without Sacrificing Control
Converting operations demand precise control, as even small variations in materials, tensions, and line speeds can impact quality and throughput.
Quad Plus delivers converting machine control systems that coordinate motion, tension, and drive performance. These systems stabilize web handling, reduce variability, and support high-speed converting operations across new and existing equipment.
With deep industry knowledge and advanced system diagnostics, our engineering team works to optimize every component of your operation, from drives and motors to HMIs, PLCs, and process instrumentation.
We support converting operations through:
- Integrated system solutions built for complex converting machines.
- Precise tension and motion control for demanding web processes.
- Line optimization focused on speed increases and stability.
- Process expertise across a wide range of converting applications.
- Technical execution and control standards supporting high-performance converting systems.
- Controlled winding and unwinding for stable material handling.
Results: Higher speeds. Stable webs. Precise Control.
Why Quad Plus?
As an experienced industrial system integrator, our system-oriented approach and application expertise allow us to design and deliver optimized automation solutions for converting machines and processes. Using proven engineering methods and process measurements, we develop the control systems needed to support reliable production.
We will engineer, design, program, and install automation systems for industrial lines from the ground up. Each system is designed to meet the requirements of your converting machine retrofit. This includes mechatronic reviews, line optimizations, speed increases, and system field services. We provide on-site and remote support to keep your operation up and running. In addition, we partner with control system parts manufacturers to ensure fast sourcing and fair pricing.
The Role of Converting System Integration in Streamlining Operations
No matter your converting application, we can help. Our engineering and service team has the expertise to build, power, and maintain every system from the simplest to the most complex. From casting, extrusion, and laminating lines to high-speed continuous coaters, Quad Plus has the record and experience to back it up.
There are certain methods of control for all web handling applications known as “sectional control.” These methods include tension control, electronic gearing, positioning, various torque controls, and turreting winder algorithms. Our team determines where these controls should be implemented. Using a detailed review of the mechatronics and web-handling scheme, we establish the appropriate sectional control strategy.
After determining the required sectional control type, our engineers select the appropriate automation products to meet the high-speed demands of your converting machine. The drives and automation products are standard, user-friendly devices selected with the customer’s specifications in mind. End-user equipment standards and preferences are important considerations when selecting automation products.
For retrofit projects, we work with your staff to upgrade existing control systems. Successful upgrades require knowledge of both the existing controls and current control-concept standards. With OEM systems, our control team works with the electrical and mechanical teams to achieve the look and feel that the OEM expects to provide to its clients.
We provide secure remote diagnostics, on-site service, and repairs. That means faster troubleshooting and less downtime. Plus, we partner directly with control systems parts manufacturers to save you time and money.
Optimizing Web Handling Systems with Precision Converting Solutions
During the converting process, either closed-loop or open-loop controls are used for web handling. A closed-loop tension control system uses load cells or dancers to control speed and torque to obtain the desired tension setpoint. Open-loop controls do not rely on feedback devices. Instead, they achieve the desired tension through operator-controlled motion or torque control. Our team of control system engineers can help you achieve the desired results by adjusting the controls on your converting system.
Maximizing Output with Advanced Converting Machine Technologies
Modern converting machine technologies combine advanced controls, motion systems, and engineering analysis to improve throughput without sacrificing product quality. Optimizing these systems requires evaluating mechanical performance and control strategies to achieve higher operating speeds while maintaining stable production.
Quad Plus engineers and technicians have a long history of optimizing coating lines and converting machines. Recalibration of controls, using mechatronics and empirical measurements, is necessary to ensure the line runs at optimal speed while maintaining the highest possible levels of performance and quality.
We begin by evaluating the mechanical gearing and HP capabilities of the sectional control before recommending performance improvements. Next, the team analyzes the drive section and measures the reflected inertia on the motor shaft. Adjustments are then made based on the findings. Finally, we will retune the outer loops as necessary to achieve good tension control with minimal deviations.
For line speed increases, we first review machine mechanics and process variables to determine whether higher operating speeds are achievable.
Optimizing the Converting Process with Advanced Automation Systems
Quad Plus combines expertise in web handling, control systems, and integrated web converting lines to support a wide range of applications. Our proven experience helps define lead (master) sections, establish tension zones, and determine whether drive control modes are needed. Our process engineers are knowledgeable in delivery, batching, and dryer systems.
Quad Plus professionals are skilled in control systems for coating applications. We have experience in engineering and commissioning integrated web converting lines, including high-speed coaters up to 1200+ mpm (3900+ fpm).
Quad Plus will ensure smooth laminate application during the converting process. Our specialty is the installation and calibration of “lay flat” controls to eliminate wrinkling, improve quality, and reduce cost.
Our process control engineers have the skills to fine-tune your extrusion and extrusion laminating lines. To control the extrusion process, our team will design and adjust both control concepts and sectional controls.
Whether the final product is film, foil, or paper, the slitting process allows bulk rolls to be slit into narrower rolls. Control concepts, sectional controls, and sequencing are used to deliver the best performance during this demanding step.
The winding and unwinding process on any converting line is among the most critical operations. Our engineers have the training and process experience to configure and program the tension control system used during winding.
Leveraging Automation Systems for Industrial Lines in the Converting Industry
Reliable automation systems for industrial lines depend on consistent engineering standards, experienced commissioning, and coordinated control strategies. Quad Plus applies proven engineering practices throughout every stage of design, programming, and startup to help ensure reliable long-term operation.
Strict control standards are critical to achieving consistent quality in converting operations. Our experts undergo specialized training to meet those expectations, including Quad Plus techniques to understand web handling. We have in-depth knowledge of manufacturers’ settings and controls. This allows us to calculate tolerances and tension accurately. This helps ensure consistent process quality across materials.
The lead startup engineer on your converting system will have been part of the design and programming team. It is critical that they are involved throughout the process to ensure the startup goes smoothly. To learn more, please visit Commissioning.
Winding and Unwinding
Stopping or slowing production during roll changes is rarely an option. Quad Plus understands that the converting machine must maintain normal line speed and tension during roll changes. Our specialists have in-depth knowledge of feedback devices such as dancers, pendulums, load cells, and encoders to control the splice, speed, and tension. The result is better performance with no downtime.
New Line Unable to Run at Capacity Case Study
A brand-new line in the acceptance testing phase was presenting persistent system faults. A systematic evaluation of the entire system, installation, and programming was required. The inspection first confirmed a clean installation, properly terminated leads, correct motor cables, a well-designed cabinet, and a correctly installed fieldbus. The investigation then turned to the encoder feedback. Switching noise was detected, and the encoder was wired for unipolar operation, a method not ideal for heavy industrial applications. Once the encoders were rewired and the system reconfigured, the customer was able to operate at full capacity.
At Quad Plus, we understand that testing and verification are a critical part of any installation. Engineering and design skills are only the beginning. Our expert-level troubleshooting and diagnostics are also available whenever you need support.
Services Available
As an industrial system integrator, Quad Plus offers a wide variety of services to assist you, no matter where you are in the system integration lifecycle. For new builds, we offer design and project management services. For existing plants, we can help your converting machine run more smoothly and efficiently. For plants with obsolete control systems, we can assist with retrofits and upgrades. No matter your business need, we have you covered!
Improve Efficiency with Expert Converting Machine Solutions
Maximizing the performance of your converting machine is crucial for consistent, high-quality production. Quad Plus offers customized solutions to enhance your machinery’s efficiency and reliability. Contact us today to optimize your converting systems and keep your operations running smoothly.
Frequently Asked Questions
Automating the converting process helps reduce downtime, minimize material waste, improve product consistency, and optimize machine performance. These improvements can lower operating costs while increasing throughput and extending equipment life.
Converting machine automation systems are used across a wide range of industries, including paper, packaging, plastics, films, nonwovens, tissue, textiles, roofing materials, and other continuous web manufacturing processes. Automation helps improve quality, throughput, and operational reliability regardless of the material being processed.
Integrating web converting equipment improves line coordination, increases production efficiency, enhances product consistency, reduces manual intervention, and provides greater visibility into overall converting performance. Proper integration also supports easier troubleshooting and future system expansion.
