Unwinder - Rewinder machines by Spark Machinery

Main features of our unwinder rewinder machines

Versatility & materials

Spark Machinery’s unwinders and rewinders deliver unmatched flexibility for modern production lines. They handle a wide spectrum of materials, from plastics and films like LDPE, LLDPE, HDPE, PP, PVC, BOPP, CPP and PET, stretch, cling films, paper, aluminium foil, laminates, non-wovens, and specialty textiles. Even challenging substrates like foam, Tyvek, and raffia are managed with precision. Designed to integrate seamlessly with our perforation systems, these machines ensure consistent tension, alignment, and roll quality across packaging, medical, industrial, and specialty applications—so you can process any material with confidence and efficiency.

Multi-Rolls Capability for Macro Perforation

In macro perforation processes, the system can be configured to unwind and rewind up to four rolls simultaneously, ensuring high productivity while maintaining precise tension control and alignment across all webs.

Tension and Edge Control

Spark Machinery's Winder-Rewinder is engineered for maximum precision, ensuring flawless material handling through advanced tension and edge control systems adaptable to a wide range of materials and processes.

Precision Tension Management

The system integrates flexible mechanical and electronic solutions to guarantee stable and accurate web control throughout the entire process:

• Unwinder Tension Control:
  At the unwinder level, web tension can be managed either by a braking system or by an actively controlled motor, depending on the application requirements and material characteristics.

• Load Cell Rollers and Dancer System:
  Tension is continuously monitored and regulated using either load cell rollers or a controlled dancer system.

  • Load Cell Rollers measure real-time web tension by mounting the roller on precision load cells.

  • Dancer System features controlled weight and adjustable position, ensuring smooth tension compensation for sensitive or elastic materials.
    The selected solution is determined according to the type, thickness, and behavior of the processed material.

• Active Motor Control:
  When motor-driven, the unwinder motor manages both startup and dynamic braking, actively contributing to maintaining constant and stable web tension during acceleration, deceleration, and steady-state operation.

• Traction Calender (When Required):
  Where the process demands additional traction or precise speed definition, a traction calender is included. This assembly consists of a motorized, chromed pulling roller operating in conjunction with an idle rubber roller with adjustable manual pressure, ensuring controlled web transport and accurate line speed regulation.

• Rewinding Configuration:
  The final rewinding can be configured as either center-driven or peripheral-driven, depending on material properties and winding requirements, ensuring optimal roll quality and tension consistency.

Flawless Edge Alignment

Material alignment is guaranteed by an automatic centering system designed to adapt to different material types and process configurations:

• Edge Guiding Sensors:
  Depending on the material characteristics, edge detection is performed using either photocell or infrared sensors. These sensors continuously monitor the material edge to ensure accurate alignment.

• Flexible Sensor Positioning:
  The edge guiding sensors can be installed at various points along the line, such as directly at the unwinder exit or downstream after the material processing stage, according to process requirements and layout constraints.

• Automatic Centering System:
  Sensor feedback is transmitted to the centering device on which the expansion shaft is mounted, enabling continuous and precise re-centering of the coil throughout operation.

• Convenient Operator Control:
  Operators can easily fine-tune the centering behavior via a compact control panel positioned at the beginning of the line for quick and intuitive access.

Integrated Safety Systems

The winder-rewinder machine features a robust array of integrated safety systems designed for operator protection and process integrity.

• Emergency and Drive Safety: The system includes multiple latching Emergency Stop Switches positioned on both the unwinder (rear) and rewinder (front), specifically intended for use during hot perforation operations to immediately stop production in the event of material defects or irregularities such as tears, burn marks, or other processing faults. All belt-driven transmission components are protected by Fixed Covers to prevent entanglement. The film's processing path is routed internally and beneath the operator platform, ensuring safe access.

• Unwinder Access Control: The unwinder utilizes Safety Door Interlocks on the roller extraction panels that prevent machine startup if they are open. Rear access panels are secured with screws.

• Rewinder Mechanical Guards: Specific safeguards are implemented at the rewinder:

  • A Protective Guard is placed over the blade block to prevent cutting hazards.

  • Side covers protect against crushing injuries during the descent of the bobbin compaction press roller.

  • An Anti-Drag Sheet is positioned on the upper roller to limit pinch points.

• Electrical & Software Security: The electrical control cabinet is secured with Dual Key Locks and a Lockable Power Selector (LOTO) to prevent unexpected power supply during maintenance. Software access requires a Password for sensitive and advanced parameter input. A Timed Auto-Logoff automatically reverts the touch screen to the simple operator mode for unauthorized user protection.