Web Tension Controller

Key Features

• Real-Time PID Control

  Automatically adjusts motor, brake or dance behavior to maintain exact web tension during process variations.

• Microprocessor-Based Feedback System

  Continuously monitors tension data to prevent stretching, slack, or breakage.

• Integrated Load Cell Input

  Accepts direct feedback from tension sensors for closed-loop precision.

• Dual Analog I/O (0–10V)

  Allows seamless integration with drives, motors, and PLCs.

• External Start Function

  Synchronizes easily with automation sequences or operator triggers.

• User-Friendly Touch screen display

  Resistive touch screen display for easy maneuvering over the menus to do setting.

• Material Flexibility

  Works with film, foil, paper, wire, textiles, and more without recalibration.

Technical Specifications

Available Accessories

• Load Cells / Tension Sensors

  Provide live tension data for the controller to process and adjust in real time.

• Wiring Harness and Mounting Kit

  For simplified installation on machines or control panels.

• Shielded Signal Cables

  Help maintain signal integrity in industrial environments.

• Communication Add-ons (Optional)

  Modules available for RS485 and ethernet output for enhanced system integration.

• Protective Housing

  Dustproof enclosures available for challenging work conditions.

Application Areas

Puretronics Web Tension Controller is designed to work seamlessly across various manufacturing sectors where material tension is critical to quality and efficiency:

Film & Flexible Packaging

• Maintains smooth feeding and accurate registration for films like BOPP, PET, LDPE.

• Prevents defects like wrinkles, edge misalignment, and breaks during high-speed runs.

Paper & Printing

• Keeps paper tension stable during slitting, printing, laminating, and rewinding.

• Minimizes tear-outs and ensures clean edge finishes even with coated or sensitive stocks.

Foil Processing

• Controls the delicate balance needed for aluminum and laminated foils.

• Reduces chances of folding, scoring, or material sticking due to excess tension.

Textiles & non-Wovens

• Enables distortion-free feeding and winding of elastic, mesh, or woven fabric.

• Useful in garment production, hygiene goods, and technical textiles.

Wire & Cable

• Prevents wire stretching, tangling, or insulation failure during payout and coiling.

• Ensures even layering and prevents deformation during fast operations.

Battery Separators

• Handles ultra-thin separator films used in lithium-ion batteries without stretching.

• Enhance layer consistency is critical to battery safety and performance.

Use Case Examples

• Film Printing and processing: By integrating this controller into a packaging film line, one converter reduced edge defects by 35% and gained smoother roll profiles.

• Paper Printing: By integrating this controller into a packaging film line, one converter reduced edge defects by 35% and gained smoother roll profiles.

• Textile Winding: A fabric manufacturer running synthetic elastic reduced reject rates caused by tension inconsistencies resulting in better quality and fewer reworks.

Benefits

• Improves Product Quality
  Achieve consistent tension that leads to cleaner cuts, better prints, and fewer surface flaws.

• Reduces Downtime
  Automatic tension control minimizes operator interventions and emergency stops.

• Minimizes Waste
  Less tearing, wrinkling, and roll rejection means more usable product from every run.

• Easy to Operate
  Simple interface and preset tuning make it ideal for both experienced operators and first-time users.

• Compatible with Modern & Legacy Systems
  Works with both analog systems and programmable logic controls, making it suitable for new or retrofit installations.

Frequently Asked Questions (FAQs)