How to increase productivity with a converting winder?

Meler Engineering successfully completes a new converting project to increase profitability in the manufacture of abrasive sanding products. The new special converting machinery is a winder that works as a complete solution integrating several processes in one: loading, product marking, lamination and final coating.

The production advantages of a winding machine

After almost 30 years of creating abrasive products for a multitude of industries, our customer decided to consider a new manufacturing method. His idea: to increase the production speed by joining two different substrates (sandpaper and cloth) in a continuous way thanks to a winding machine.

This productive change would bring the following advantages:

• Increased production capacity: by automating the process, manual operations would be reduced and production would be faster.
• Increased quality of the final product: the winder would offer stability throughout the adhesive lamination process, as well as repeatability over the length and width of each metre of reel.

1.- Loading:

The winder is 100% accessible and has two material loading points (one of them with a removable trolley that is automatically aligned) and one for unloading the final bobbin. Both points are equipped with two splicing tables that facilitate a quick reel change.

2.- Printing

The final product is marked for identification at the point of sale. The printing system has 4 printing heads and works at a speed of 4m/s. This is the first process that takes place inside the rewinder.

3.- Laminating and substrate bonding

The adhesive comes from a high-capacity external melting plate and is applied with an adjustable head that allows a lamination width from 500 to 1600 millimetres.
The winder includes a ventilation system that provides safety when working with industrial adhesives.

Image: Micron+ Drum 200, a specialised melter for PUR adhesives, operates as prometer for continuos adhesive flow.

Once joined by the calender, the substrates advance along the winder with the help of rollers treated with a special coating that prevents damage caused by the abrasive side of the sanding substrate.

4.- Final winding

The structure has detection barriers and sensors for both diameter and presence of material, which guarantee precision and line stop while working inside the machinery. The final reel can weigh up to 550 kg.

A turnkey product

Creating turnkey products is always difficult. Communication and collaboration over 25 weeks gave rise to this new Meler project, which culminated in a start-up working alongside the customer. Two Meler technicians were responsible not only for the installation but also for giving several training sessions so that the customer had full control of his new machinery from the very beginning.

Image: winder installed at the customer’s site with two reels of end product in the foreground.

This Meler Engineering project combines several processes into a single complete solution and demonstrates Meler’s ability to adapt to customised turnkey projects.

Discover the project with the help of this video.