Web Converting Systems for Modular & Scalable Production
Modular Web Solutions delivers the web-handling expertise needed to achieve even the most challenging of processes.
What Are Web Converting Systems?
Web converting systems transform continuous raw materials such as film, foils, paper, nonwovens, and laminates into finished products through a coordinated sequence of mechanical and automated processes. These systems rely on stable tension, precise web handling, and synchronized control to maintain quality at production speeds.
The MWS Process-Driven Engineering Approach
We start by defining your converting line’s operating requirements, then design and build the mechanical and electrical systems around those parameters. Through in-house fabrication, integration, and mechanical dry runs, we deliver systems prepared for reliable startup and long-term performance.
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Process Parameters Defined First
Every system begins with defined operating requirements including line speed, substrate characteristics, tension sensitivity, coating chemistry, drying needs, environmental conditions, and automation requirements. Mechanical and electrical strategies are aligned to these parameters from the outset.
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Complete System Architecture
MWS designs and manufactures full converting systems integrating unwinds and rewinds, web guiding and tension control zones, accumulators for non-stop operation, calenders and nips, coating and laminating stations, air turn bars, and heat transfer roll systems.
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Integrated Mechanical and Electrical Systems
Mechanical and electrical systems are engineered together as part of the overall machine architecture. Drives, controls, and operator interfaces from leading manufacturers are implemented to meet application needs. Electrical panels are designed and built in-house to meet UL and CE certification when required. Tension control incorporates load cell and dancer systems, with additional integration available for advanced automation.
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In-House Fabrication and Execution
Design transitions directly into in-house machining, welding, surface preparation, finishing, assembly, and system integration within our Wisconsin manufacturing facility. Systems are assembled and undergo mechanical dry runs prior to shipment to verify alignment, motion, and overall system functionality. This controlled execution supports quality, schedule reliability, and installation readiness.
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Lifecycle Performance Support
From installation support and technical service to rebuild and upgrade projects, MWS supports converting systems throughout their operational lifecycle. We recondition, rebuild, and upgrade existing equipment and evaluate opportunities on a case-by-case basis, including supporting equipment from other manufacturers.
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