Remmele Engineering - Web Processing

Every web processing project is unique. Web width and thickness, varied materials, speed, precision alignment of multiple webs - all of this and more needs to be considered whenever you develop a new system. At Remmele, we have the experience and resources to design and build to your individual needs. We combine state-of-the-art technology with unparalleled expertise in materials and web dynamics to deliver superior results within precise specifications.

Your Product

Perhaps you're working with materials that require zero-tension or call for tolerances of .005 inches or less. Maybe you have a web width anywhere from 1 to 60 inches wide, or a precise tension-control application. Whether your processes include die cutting and laminating or island placement and heat-sealing, Remmele has the web processing expertise to help your project succeed. We have the experience to support your web processing application and provide you with the ideal integrated solution.

How Can We Help?

Below you'll find an overview of several web processing projects that offered Remmele unique and interesting challenges. See what we did for these clients...and then let us see what we can do for you.

Three polystyrene webs and one coated membrane web were die cut and ultrasonically welded together with a part repeat of approximately 1". Final product was inserted into cartridges, then individually labeled and barcoded. Remmele was the ideal partner for this client because of our ability to integrate multiple components, our expertise with validation support utilizing GAMP 4, our experience with 21 CFR Part 11 compliance issues, and our use of leading-edge control systems. Key technologies included integration of 54 servo axes and 15 PLCs, continuous motion ultrasonic welding, and SQL database collection capable of tracking 400 MB of data per day.

System 2

Battery cathode material was extruded into a web 3.5" wide by 0.030" thick. Material was cut, placed, and calendared multiple times before achieving desired thickness. Remmele understood the need for process development prior to design of commercial equipment for this project, and was able to provide calendaring precision with TIR of less than 0.0002". Our expertise at handling fragile webs (0.002" thick) further helped ensure success. Key technologies included calendaring rollers repeatable to 0.0001", real-time gap measurement and calibration within 0.0001", and matched servo gearing within 0.25% of set point.

System 3

Three webs - a carrier web, black anode material, and a cellophane separator - traveled at different rates of speed before joining to form a composite web. The anode and cellophane materials were slit, rotary die cut, island-placed onto the carrier web, and hermetically sealed with a line speed of 160 ft/min (2,560 pcs/min). A vision inspection system determined product quality and monitored process trending. Remmele offered the perfect blend of technology and expertise for the numerous process characteristics of this application. Key technologies included island placement within +/- 0.005", hermetic sealing, web cleaning, rotary die cutting, and high speed servo controls.