Inline winding system for demanding cleanroom applications

Winding processes in cleanrooms call for precision, minimal manual intervention and a seamless handover into the downstream process, not as a nice-to-have but as a technical necessity. With the automatic turret winder ATW-600/1900 I TAC we have built a fully automated inline solution that meets exactly these requirements, and does so without a single production stop.

The starting point of the project was a continuous winding process in a high-purity production environment. Cleanroom applications come with their own particular conditions, because every manual intervention in the running process is a potential source of contamination and defects. Downtime caused by roll changes, time-consuming core loading or the need to remove finished rolls by hand is not only inefficient in such environments, it also puts product quality at risk when it matters most. The requirement was therefore clear, namely a system that is fully integrated into the production flow, meets the highest cleanroom standards and runs uninterrupted throughout.

The technical solution, fully automated from core to handover

At the heart of the machine sits the TAC (Tape and Cut) module, which carries out the roll change fully automatically and without interrupting the production flow. As soon as a roll reaches its target diameter, the system initiates the change on its own, cuts the material precisely, attaches it to a new core and continues the winding process seamlessly. In practice this means no manual intervention for the operator, no production stop and no quality loss at the cutting point.

The automatic core feed makes sure that new cores are supplied continuously, positioned precisely on the winding shaft and prepared with adhesive tape by an integrated core preparation system. This fully automated sequence eliminates one of the most common sources of error in the winding process, namely faulty or inconsistent manual core loading, and at the same time creates reproducible conditions for every single winding cycle.

The integrated slitting system delivers a precise cut and produces clean, well-defined edges even on demanding materials. The winding shaft extractor then allows direct, labour-saving roll removal whose ergonomics are comparable to a shaftless winder, since finished rolls can be taken out without elaborate shaft assembly or additional handling steps.

Automated roll removal and seamless process integration

A customer-specific unloading cart takes the finished rolls out of the machine fully automatically. This handling system, tailored to the actual application, makes sure that roll removal also runs without manual intervention and without interrupting cleanroom operation. A downstream conveyor belt transfers the finished rolls directly into the next process step and thus closes the process chain completely.


The result is a true inline process in which material enters and finished rolls leave, without anyone having to lay a hand on it.

Economics and process stability in the cleanroom

The ATW-600/1900 I TAC really plays to its strengths with small roll diameters, which are common in cleanroom applications. Short cycle times and fast roll changes lift overall system productivity noticeably. Simple core loading directly inside the winder reduces operator workload to a minimum, and the direct removal of finished rolls without time-consuming dismantling of the winding shaft saves additional time and personnel effort.

Our approach to special-purpose machinery does not end with delivery. We accompany projects from the initial requirements analysis through engineering and assembly and into ongoing production, including commissioning with original material, operator training and continuous support. Only once the system runs reliably and stably in everyday production is our quality standard met.

If you are facing similar challenges, feel free to get in touch. We will be glad to show you how the ATW-600/1900 I TAC can take your winding process to the next level as well.