Versatile Turret Winder for Flexible PVC Film: Automated, Modular and Precise

We developed an automatic turret winder for a leading film manufacturer with a production site in the United States. The machine handles thin, flexible plastic films with particular care throughout the winding process. Fluctuations in web tension on the existing calender line had impaired winding quality and led to customer complaints. With very little floor space available, we combined precise web tension control and automatic reel handling in an exceptionally compact design.

The manufacturer produced flexible PVC film on an existing calender line equipped with a conventional turret winder. Web tension fluctuated during operation. With thin and flexible films, even small deviations directly affect reel build. The resulting quality problems led to customer complaints.

The new winding solution therefore had to wind sensitive films reliably at very low tension through to the last layer while also supporting higher web tension levels for other applications. It also had to support continuous operation of the calender line within a tightly constrained footprint.



Plastic films respond differently to web tension depending on their properties. At the same time, reel changes, in-line slitting and unloading must be integrated reliably into the material flow.

Precise Control of Web Tension and Slitting

To meet these different winding requirements, we designed the contact roller carriage with two control modes. At low web tensions, the machine uses dancer-roll control. At higher tension levels, a tension load cell provides the control signal. This allows web tension to be matched to the properties of each film and the specific winding task.

For an even reel build, web tension, contact pressure against the growing reel, web speed and film properties must work together precisely. By configuring the control system for the application, we can guide even thin and flexible films reliably, including materials that are especially sensitive to tension fluctuations.

In-line slitting remains adjustable during production. Pneumatically actuated blade holders allow the knife position to be adjusted while the web is running and the blade to be engaged when required. If one blade is worn, the second blade holder takes over the cutting process. The freely accessible holder can then be removed and fitted with a new blade while the web continues to run. The video demonstrates this blade-change procedure directly on the machine.

Automated Reel Changes and Unloading

The machine switches automatically between two winding stations, supporting continuous in-line production. Once the specified reel length is reached, the next winding station takes over the moving web, allowing the calender line to continue without a manual reel change.

After the reel change, the mobile unloading cart takes over the finished reel. It travels into the machine and positions itself at the winding station while an integrated winding shaft extraction device withdraws the winding shaft and sets it down on the cart. The cart then moves to the designated unloading position. This shortens handling distances, reduces manual steps and integrates reel transfer into the downstream material flow.

Compact Design Tailored to the Site

Because space was extremely limited in the existing production area, the site constraints shaped the turret winder from the outset. We developed a more compact version for the customer that could be integrated into the existing calender line and material flow while retaining all required functions.

During engineering, we considered spatial integration together with the mechanical and control-system requirements. The result was a custom machine that makes full use of the available footprint and combines winding, reel change and unloading functions in a coordinated overall concept.

Modular Design Creates Options for Future Expansion

The modular machine platform gives the manufacturer several options for expanding the slitting technology and reel handling. Depending on the production task, another slitting system can be integrated or the unloading cart can be automated further.

For maintenance and process adjustments, our service technicians can access the machine control system through an encrypted VPN tunnel once access has been authorized. This allows them to review settings, optimize operating sequences and add suitable control functions, even when the machine is operating internationally.

From a Quality Issue to a Custom Turret-Winding Solution

The web tension fluctuations, quality problems and customer complaints on the existing calender line defined the requirements for the new machine. Based on these requirements, we created a turret winder that combines the sensitive winding requirements of thin, flexible PVC films with the spatial constraints at the US production site. Precise web tension control, compact design and automatic reel handling work together within a fully coordinated system.

Develop Your Winding Concept with Us

Are you planning continuous film production or a comparable application and looking to automate more of your production line? Talk to us about your material, the required operating sequences and the process improvements you want to achieve. Together, we will develop a winding solution that integrates precisely with your line and offers the right options for future expansion.