2015 BWCN Newsletters - Web Tension Control and Better Web Control News

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Newsletter Archives: 2015 Better Web Control Newsletters

Montalvo’s Better Web Control Newsletter delivers Montalvo and industry news directly to your inbox once a month. Stay up to date on the latest product releases, technology developments and headlines conveniently through your e-mail.

December 2015 Better Web Control Newsletter

In this issue:
BWC Blog: Direction of Force
BWC Blog: Zero Drift
Magnetic Particle Brakes
Plan for 2016!

BWC Blog: The Importance of “Direction of Force”
When Calibrating Load Cells

When calibrating your load cells, first make sure you are always following the proper calibration procedure when troubleshooting.

Reference your tension controller technical manual to verify that the load cell cables are terminated in the controller correctly, and securely.

Secure one end of a rope, and follow the web path at least one idler roll before, and one after the load cell roller.

Free hang a known weight that is at least 25% of the expected tension setpoint.

Spin all idler rollers between the position that the rope is secured, and all rollers, including the load cell roller, to break the friction between the rope and the rollers. This will insure a more accurate tension reading from the load cells.

Follow the calibration procedure on the controller to complete the tension controller calibration. If you are still receiving any errors, or more specifically are seeing a “weight too small” message on your tension controller, a quick look at your load cells may reveal the source of the problem.

The direction of the force arrow labels on your load cells must match the direction of resultant force on your application’s rollers from your web of material. So if your resultant force is straight down, then the load cells must be in a position where their force arrow labels are also pointing straight down. If utilizing two load cells on a roller then each load cell force arrow labels must be pointed in the correct direction.

Without matching force directions, the load cells will be unable to detect the full amount tension being applied to the roller.

If you find that your load cell’s force arrows direction do not match the direction of resultant force, you will need to rotate the load cells to the correct position. Once the load cell(s) are correctly positioned to match your direction of force, follow your tension controller calibration procedure once more.

For additional assistance Montalvo’s Applications Specialists are always available to you. Please contact us any time.

BWC Blog: Causes and Cures for Tension “Zero Drift”

When you have no material in your machine and the tension reading is indicating something other than zero you are most likely experiencing “zero-drift”.

There are several possible culprits, and one needs to examine the entire system to best provide the solution. The components involved include the load cells, cables, the idler roll, bearings and shafts, and the tension signal conditioner or amplifier.

Many people wonder since calibration affects zero, and they calibrate at the amplifier or controller, that this is the culprit.

The logical place to look is the load cells. In order to provide precise and accurate readings, the load cells must be very sensitive to small changes in load. There are basically two types of loads applied to the load cells. The force that we are interested in is the force that is applied by the web, which is directly proportional to the tension. Then there is what we call pre-loading. These are forces that the load cells see that have nothing to do with tension. They are due to the weight of the roller assembly supported by the load cells, plus forces exerted on the load cells during the mounting process. The roller assembly weight is a constant and if the mounting procedure is followed precisely these forces can be minimized to be as constant as possible and, while they are still seen by the load cells, they can be electronically “zeroed” and not “seen” at the amplifier output. Unfortunately, proper mounting procedures are often not followed.

The following is a troubleshooting guide:

Read the full post and get the guide here.

New Product: Magnetic Particle Brakes
Ideal for clean room and other sensitive environments.

MP-B Series Brake with VC2 Voltage Converter

MP-B-650 Brake with VC2 Voltage Converter

Smooth, repeatable, high quality performance with no dust. Ideal for clean room environments, the MP-Series provides the precise, smooth torque control you require from full roll to core, maximizing your process capabilities.
MP-B Series brakes are available in shafted or thru bore models with torque ranges from 0.4 in-lb (0.04 Nm) up to 8,851 in-lb (1,000 Nm).

MPB Features:

No Dust – Perfect for Clean Room Environments
Long Maintenance Free Service Life
Easy Installation
Wide Torque Range – Multiple Models Provide Torque Ranges up to 8,850 in-lbs.
Reliable, Repeatable, Accurate and Smooth Torque Delivery
Rapid Response to Any Torque Changes
Smooth Starts and Stops
Silent Operation

For a full list of features and more information visit the MPB Series Product Page

Start Strong in 2016!
It’s the perfect time to get your tension control upgrades in the books and geared up for a more successful 2016!

Wondering what to do with the rest of your 2015 budget?

Are you potentially in a use or lose it situation?

Want to get some spares on the shelf?

Just want to get ready for a more successful 2016?

We can help!

As 2015 nears its end, it’s the ideal time to start preparing for 2016, while capitalizing on your remaining 2015 budget.

A tension control upgrade is an extremely cost effective method for adding increased capabilities and productivity to your machine. Whether it’s just a few key component upgrades or a larger tension control retrofit, Montalvo gives you the performance enhancements you require for years to come.

Reduced scrap
Increased line speed
Higher quality end product
Easier operation
Reduced maintenance

These are just a few of the possible benefits you can achieve through a Montalvo tension control upgrade.

Talk to an Applications Specialist today to see what options make the most sense for your particular machine, budget, and 2016 goals.

November 2015 Better Web Control Newsletter

In this issue:
BWC Blog: Why Dancer Controller with Indication
Featured Product: Z4-UI
Plan for 2016!

BWC Blog: Why would I need a Dancer Controller with Tension Indication?
In this entry we look at the benefits of a multi purpose dancer controller

“Processes that require rapid acceleration and/or deceleration, or processes that may deal with out of round rolls, all benefit from utilizing a dancer due to their web storage capabilities. A well designed dancer system with a quality dancer controller is an excellent method of managing web tension.

However, no dancer system can tell you what your actual web tension is. The tension can be inferred, but without load cells providing direct web tension measurement from your material, actual tension will not be known. For some processes this is perfectly ok, as the dancer and dancer controller will provide sufficient tension control. But for processes requiring even greater process consistency, whether from run to run, or shift to shift, or if a range of materials are run on this same machine with varying tension requirements, or you simply require a greater level of precision and accuracy in your control, web tension measurement utilizing load cells is the way to go.

Some tension control suppliers will say it needs to be an either or decision, load cells or a dancer, as they do not offer a dancer controller that can capitalize on and utilize load cells or vice versa. Montalvo says you should, and can, have the best of both worlds.”

Read the rest of this post

Z4-UI Dancer Controller with Tension Indication
Unwind tension zone control utilizing dancer arm and load cell feedback

z4 dancer tension controller with tension indication

Unwind Zone, Dancer and Load Cell Feedback

The Z4-UI is the next step in Montalvo’s dancer tension controller technology. As the originators of the first dancer controller capable of utilizing load cell feedback, the Z4-UI continues the tradition of producing high quality, high performance tension controllers that offer advanced features and functions while still being easy to set up and operate.

Maximize your dancer process control with the Z4-UI.

Additional features include:
Compatible with dancer position sensors, ultrasonic sensors, prox. switches, lasers and potentiometers
7″ HD Interactive Display Screen
7 day application run data storage
Remote installation and multiple mounting options
24V version available
Compatible with pneumatic and electrics brakes and clutches
Compatible with drives

Get more information on the Z4-UI

Start Strong in 2016!
It’s the perfect time to get your tension control upgrades in the books and geared up for a more successful 2016!

Wondering what to do with the rest of your 2015 budget?

Are you potentially in a use or lose it situation?

Want to get some spares on the shelf?

Just want to get ready for a more successful 2016?

We can help!

As 2015 nears its end, it’s the ideal time to start preparing for 2016, while capitalizing on your remaining 2015 budget.

Reduced scrap
Increased line speed
Higher quality end product
Easier operation
Reduced maintenance

These are just a few of the possible benefits you can achieve through a Montalvo tension control upgrade.

Talk to an Applications Specialist today to see what options make the most sense for your particular machine, budget, and 2016 goals.

October 2015 Better Web Control Newsletter

In this issue:
BWC Blog: Motors vs. Clutches
Article: Clutches for Superior Center Winding
Rewind Tension Control

BWC Blog: Clutches / Brakes or Motors?

We take a look at the advantages of each so you can decide what’s best for you.

Excerpt: “When comparing brakes (unwinds) and clutches (rewinds) to motors, there are significant advantages and disadvantages that must be considered to determine the best component for your application currently and in the future. Here we take a quick look comparing brakes and clutches to motors in 7 key categories.

Acceleration
Unlike a brake, a motor can drive a roll of material to maintain precise tension during the acceleration of the roll. This is very important if you are running large rolls of very delicate materials (such as tissue paper) or materials that are very extensible. A driven unwind can also help with achieving proper registration during acceleration faster than a brake system, although this usually requires the addition of a servo, which can be more complex to install, commission, and maintain. Advantage: Motors
Cost
Motors are significantly more expensive when compared to a brake or clutch. Not only are the individual components as much as 2-3 times more than a brake/clutch, the installation and service usually require personnel that are very familiar with drive controllers, PLCs, etc. When comparing brakes/clutches to motors/drives always look at the total system cost plus support, and how easily the system can be upgrade modified later on (if ever needed). Advantage: Brakes and Clutches”Read the entire post

Using Clutches for Superior Center Winding

Tension Control Technical Article

Excerpt: “Proper component selection is critical to ensure the success of building a center-driven rewind stand. While many factors need to be taken into consideration, ultimately it is the quality of the wound roll that is of prime concern. Material advances have presented a host of challenges for machine designers to overcome to ensure proper wound roll quality. From lightweight, extensible films and non-wovens, to foils and even non-traditional materials, choosing the proper method and equipment can mean the difference between failure and success.

Clutches are not often chosen to control tension on center winders because their proper application and the advantages of using a clutch with a motor are usually not understood.

Usually, when one finds a clutch-controlled center winder, the clutch is “geared in” to run 50 RPM faster than line speed at core. The clutch is usually driven by a constant RPM AC motor, and therein lays the crux of the problem.

As the diameter of the roll increases, the torque at the clutch must be increased proportionately to maintain a constant tension profile in the web. As the torque and roll diameter increase, the slip speed of the clutch also increases as a result of diameter increase.”

Read the Entire Article

Rewind Tension Control – Finish Strong
Solutions to Maximize Your End Product Quality

Rewind Zone, Load Cell Feedback

Maximize your end product quality by finishing just how you started; with precise, accurate, consistent tension control.>We manufacturer some of the best web tension control products designed specifically for the unique processing variables found in rewind applications.

Our rewind tension controllers offer inertia compensation, taper, web break detection and more to ensure you don’t sacrifice quality and produce waste right at the end of your process.

Montalvo load cell’s provide reliable, precise and sensitive tension measurement while our clutches give the smooth, consistent torque you require to build high quality rolls and offer greater advantages over motors.

Learn more about Montalvo Rewind Tension Control Solutions.

Talk to a Montalvo Rewind Application Specialist today

September 2015 Better Web Control Newsletter

In this issue:
Torque Sensing Control System
What is Extended Range?
Analog in a Digital Age

Torque Sensing Control System™
Open loop tension control is more accurate and precise than ever before

torque sensing control system with ultrasonic sensor option

TSC System with US4 Option

For the first time ever in an open loop control system, you get a precise, reliable tension reference that operators can use to ensure consistent, high quality production runs without load cells or a dancer.

Patent pending technology allows easy integration into existing machines as well as new machine builds.

Customize your TSC™ packages based on your needs and the products you currently have. TSC™ components can include the U4 Tension Controller, V or CS Series Brake, TS Torque Sensor, US4 Ultrasonic Sensor or Proximity Switches, M4 Meter, and an MPC4 I to P Converter

The TSC™ is ideal for applications where:

The machine cannot accommodate load cells or retrofits (space limitations, costs, etc.).
There is no defined web path or web is traveling directly from unwind roll into the process.
The web cannot be contacted after unwind by rollers or requires minimal roller contact (coating, films, foils, etc.).
Multiple unwind stands that each require cost effective, simple control, and a simple web path (sheeters, laminators).
Existing open-loop system, but want to improve consistency and quality of your production.
Utilizing a PLC or similar system and want to control torque with minimal modification and effort.

Learn more about the Torque Sensing Control System™

BWC Blog: The Myth of Extended Range
Understanding what it all means.

A customer recently asked us how our load cells compared to other manufacturers that promote “extended range load cells”. These extended range load cells utilize a 10V excitation with the claim that by using a higher excitation you get a more sensitive tension signal. For reference, Montalvo’s load cells utilize a 5V excitation.

So the idea is that for a 100 lb load cell with a 5V excitation, you would get 125 mV of output, whereas with an “extended range” load cell you would get 250 mV of output due to the 10V excitation. The sales pitch is that with double the input, you get double the output and thus have a more sensitive load cell for detecting any changes in tension.

Unfortunately the reality is that this does not affect the sensitivity of the load cell.

Mathematically, sensitivity is equal to Change in Input divided by Total Output (S=CI/TO)

So in our two examples:

Example A: 125 mV / 5 V = 25 (mV/V)

Example B: 250 mV / 10 V = 25 (mV/V)

Increasing the excitation voltage doesn’t change the end result at all. Also note that this value is independent of the amplifier used, so even using a more sensitive amplifier will not have an impact on this.

When choosing the best load cell for your application focus on quality, true performance, and the support you will receive, and don’t be fooled by the myth of “extended range”.

View this post online

BWC Blog: Analog Meters Still Have Their Place

The benefits of analog in a digital age.

While much machine information today is displayed with digital meters, analog meters still have their place in the industrial world. One such application is the display of tension in a running web.

The tension on the web is affected by many mechanical factors in the process. When unwinding a roll of material, the quality of the roll itself is a major factor. If this roll is not perfectly concentric, which is usually the case, this will cause speed differences which will result in tension differences. The same applies to worn air shaft journals, safety chuck journal seats, as well as worn core chucks.

Other factors can be worn bearings, the web slipping on rollers, vibration due to non balanced rolls, worn gears or unstable drives. Some of these problems are easy to correct but many are not. Many do not have a major impact on product quality.

Since the tension is measured by highly sensitive and accurate load cells, these mechanical issues will be displayed as fluctuations in tension. In high speed applications, the refresh rate of a digital display or the inherent dampening of an analog meter will smooth out these fluctuations and give a good indication of the “average” tension.

In slower speed applications, these fluctuations will be much more pronounced and it can be very difficult to determine what the “average” tension is. One advantage of the analog meter in this situation is that it can be used to troubleshoot the problem. For instance, if the tension fluctuation is in sync with each revolution of the unwind roll, this will obviously indicate where the problem lies. It will then be easy to determine if it is a worn component that can be corrected or a non concentric roll which you may have to live with. Digital meters, on the other hand, will not show an easy to read “trend”.

Another advantage of the analog meter is that it is very easy to dampen. Simply connect an electrolytic capacitor to the connector of the meter. Any value between 100 and 300 microfarad should work. Just be sure to connect the positive of the capacitor to the positive of the meter. See Drawing.

View this post online

August 2015 Better Web Control Newsletter

In this issue:

Z4 Load Cell Tension Controller

Blog: Ultrasonic vs. Proximity Sensors

Z4 Tension Controller – Utilizing Load Cell Feedback

Unwind – Rewind – Nip/Process Control

Z4 Web Tension Controller

Montalvo’s newest web tension controller, the Z4, utilizes load cell feedback to provide precise, consistent and high quality tension control for your unwind, rewind, or nip/process tension zones.

The Z4 has a full range of features and functions specific to the unique variables found in each tension zone like soft-start for unwinds, and taper for rewinds, to ensure the highest quality results from start to finish.

Other features include:

7″ HD Interactive Display Screen
Trend Storage
Remote Installation and Multiple Mounting Options
Integrated Tension Indication (remote and enclosure versions)
User Defined Units and Scale
and much more

Full a full list of features and functions of the new Z4 check out the individual product pages on montalvo.com

Check out the Z4 Unwind Load Cell Controller (Z4-UL)

Check out the Z4 Rewind Load Cell Controller (Z4-RL)

Check out the Z4 Nip Load Cell Controller (Z4-NL)

Ultrasonic vs Prox Switches for Diameter Measurement

A brief look at the advantages and disadvantages of each.

When deciding whether to use an ultrasonic sensor or proximity switches for you diameter measurement it is important to know the advantages and disadvantages of each so you can utilize the best device for the unique requirements of your process.

In our newest post we take a quick look at proximity switches and ultra sonic sensors to help you decide.

Check out the blog post

July 2015 Better Web Control Newsletter

In this issue:

New Video: TSC Demonstration

New Guardian Safety Chucks
New Z4 Tension Controller

Torque Sensing Control System Video Demonstration

Check out the latest innovation in open loop tension control.

For the first time ever in an open loop control system, you get a precise, reliable tension reference that operators can use to ensure consistent, high quality production runs.

Check out the video to see this new technology in action and what it means for increasing your productivity and profitability.
Watch the Video

Learn more about the Torque Sensing Control System

New Guardian Safety Chucks

Shorter lead times, increased performance and lower total cost of ownership.

Introducing our newest line of performance driven safety chucks – The Guardian Series.

Guardian Safety Chuck and Replaceable Inserts

Safety Chuck & Replaceable Inserts

All new hardened replaceable inserts save manufacturer’s time and costs by only needing to replace the inserts as opposed to an entire handwheel when maintenance is needed, and can be replaced quickly and easily. New inserts also add versatility as they can be swapped out to accommodate other shaft sizes on the same safety chuck. Guardian Safety Chucks also feature an increased safety factor (A2), longer service life, easier roll loading and has the lowest total cost of ownership in the industry.

President Ed Montalvo says “The Guardian Safety Chucks represent the next evolution of our safety chuck line as we incorporated all the elements of our KL line that made them the preferred safety chucks for manufacturers while adding new functionality and features to create a new patent pending product. Manufactures are able to protect their machine operators and their rolls while decreasing lifetime costs, reducing maintenance time, and utilize a higher performing safety chuck.”

For a full list of features and for more information on the All NEW Guardian Safety Chucks please visit the G1800 Product Web Page

The New Z4 Tension Controller – Available Now

Official announcement coming soon!

Z4 Web Tension Controller

7″ HD Interactive Display Screen

Control Any Tension Zone

Unwind
Intermediate (Nip)
Rewind

Utilizes Multi Feedback Sources

Load Cells
Dancer
Both

Full Range of Features and Functions

Stay tuned for our official Z4 Launch Announcement.

See the entire line up of Z4 Tension Controllers

Contact your local Montalvo Applications Specialists

June 2015 Better Web Control Newsletter

In this issue:
BLUE Lifetime Assurance
ES Size 1 Load Cells

Montalvo BLUE Lifetime Assurance

Here for you!

The Standard for Reliability, Dependability and Performance

Since 1947 Montalvo has been providing the web tension control products, services and support our customers depend on to maximize their process productivity. We are committed to providing you our very best in every way, being there for you, whether its just a question or a complete tension control upgrade.

BLUE Lifetime Assurance is the embodiment of that commitment to you.

Our industry, application, and process knowledge has become an industry standard and our uncompromising service and support let’s you know we will always be there for you.

Learn More

All New ES Size 1 Dead Shaft-Idler Load Cell

Drop in and upgrade the capabilities of your machine.

We have expanded our range of sizes of the ES Dead Shaft-Idler Load Cell to ensure full dimensional equivalency regardless of the type of machine you are running.

The New Size 1 joins the current size 0 and 2 models. With three sizes the ES-I load cell can easily be installed into machines to replace existing load cells or within the dimensional requirements of new OEM machines.

ES-I load cells are designed to be used in applications utilizing dead shaft idler rolls that require high quality and high performance load cells with longer service lives.

Read the Press Release

Get more information on the ES-I Load Cell

May 2015 Better Web Control Newsletter

In this issue:
Load Cells
Product Line – Load Cells
The Importance of Load Cells

How You Measure Makes All the Difference

Quality – Performance – Precision – Repeatability

Load Cells are not always front and center in people’s minds, perhaps even viewed as a commodity. They are often a small component in a large machine, and depending on the environment perhaps not even visible.

However, a poor performing or inferior load cell can take the thousands, hundreds of thousands or even millions invested into a machine and put that money in the trash, in the form of increased scrap, slower production speeds, poor end product, and more.

That’s why we’ve dedicated this entire newsletter to Load Cells!

When you need a load cell, you need one that is sensitive to the slightest changes in tension, one that is built of the highest quality, one that delivers incredible performance, gives you a repeatable signal every time, and has a long service life. When you need a superior load cell, you need a Montalvo Load Cell.

Learn More

We’ve Got the Load Cell You’ve Been Looking For

A full range of load cells to meet the specific needs of your application

High quality tension control starts with a high quality tension control signal. Montalvo’s strain gauge load cells offer industry leading sensitivity to detect the slightest changes in tension, minimizing waste and maximizing your amount of high quality end product.

We manufacture a full line up of load cells to meet the specific needs of your application, delivering the reliability, performance, and service life you depend on.

ES Series (Dead/Idler Shaft, Live Shaft, Live Roller)

U Series (Under Pillow Block)

N and XN Series (Cantilever)

XR Series (Single Strand-Filament, Ribbon, Wire, etc)

LCR and TNT (Load Cell and Rollers all in one)

View all load cells

The Importance of Load Cells

A detailed article looking at why load cells are critical to your performance.

Paired load cells connected to a roller in a web path send continuous signals to a tension controller

The trend towards faster, wider web width machinery and the processing of a broader range of substrates has resulted in a greater emphasis being placed on tension control equipment.

Without an accurate method of measurement and control, product quality and productivity will be affected. Distortions in a material, stretched as a result of excessive tension, can be just as counterproductive as folds and creases from too low a tension. Web breaks and the consequent downtime are costly affairs.

In order to control web tension, there must be continual and precise measurement of actual tension in the web in a format that is meaningful to the process line’s tension control system. That system regulates tension through drives or brakes at zones in the line that are preset to determine tension levels.

Read the rest of the article here

April 2015 Better Web Control Newsletter

In this issue:
Taper Tension
Product Spotlight MRU

Taper Tension for Rewind Control

Taper tension is sometimes necessary if you are center winding film or other extensible material. If you maintain a constant tension on the web, as the diameter of the roll increases, the wraps become tighter. This sometimes stretches the web. If the web just came from a dryer section and the film is warm when it is wound, it will tend to stretch more. Then as it cools, it shrinks to its original size and either telescopes the roll or crushes the core. Similar problems arise when winding extensible foam materials as well.

The best method of achieving taper tension is to measure the diameter of the roll, either using an ultrasonic sensor or two pulse tachometers (one on measuring revolutions of the rewind roll and one measuring revolutions of a drive roll). This measured diameter is then processed and is used to reduce the tension as the roll diameter increases. Taper Tension can be automatically controlled through a taper tension feature controller.

Read the full article

Product Spotlight MRU – Micro Rotary Union

Micro Rotary Union (MRU)

The MRU is a mechanical rotating device that allows the transfer of air to and from rotating equipment. It is used in machinery that requires a constant air flow during rotation and can operate at speeds of up to 7000 RPM with a maximum air pressure of 75 psi.

The small size is ideal for use in applications with limited space. The MRU uses micro precision instrument bearings and a carbon seal. The shaft is made of rugged stainless steel.

Features Include:

Carbon material seal designed to be effective, durable and long lasting.
Ball type, precision instrument grade bearing requiring no maintenance.
Rugged, corrosion and wear resistant stainless steel shaft.
Single piece aluminum housing body that protects the internal parts.
Low friction resistance.
Runs up to 7000 RPM and/or 75psi.

Visit the MRU Product Page for more information

March 2015 Better Web Control Newsletter

In this issue:
All NEW TSC System
ICE Europe

A Game Changer in Tension Control
The all new Torque Sensing Control System (TSC)

Have a machine that cannot accommodate load cells or retrofits due to space limitations, costs, etc?
Have no defined or a changing web path, or have the web traveling directly from the unwind roll into processing?
Have a web that cannot be contacted after unwind by rollers or requires minimal roller contact (ex: coating, film, foil ,etc applications)?
Have multiple unwind stands that each require cost effective, simple control, and a simple web path (ex:
sheeters)?
Have an existing open loop system and want to improve consistency and quality?
Have a PLC or similar system and want to control torque with minimal modification and effort?

If you experience any of these within your application then the new TSC System can deliver the accuracy, consistency and quality tension control you require to expand your production capabilities.

For more on how the TSC System works, benefits, or to learn more about how the TSC can easily integrate into your machine please…

View the TSC System overview sheet

Contact an Applications Specialists

ICE Europe 2015 Hall A6 Stand 481

See our latest tension control technology Z4, Guardian Chucks, and TSC System

Over the past year we have been working hard at developing some real industry game changers, and they are making their debut at ICE.

The Z4, Guardian Chucks and TSC System offer a variety of new functions, features, and patent pending technology that the industry just hasn’t seen before, and will truly improve the capabilities of existing and new machines.

In today’s competitive landscape every advantage matters and these products deliver.

Z4 Tension Controller

Configurable for Unwind, Nip/Intermediate, or Rewind Zone Tension Control the Z4 combines performance, functionality, and ease of use into one package.

Guardian Safety Chucks

Longer service lives, easier loading, increased safety factor and the lowest total cost of ownership in the industry. Our patent pending Guardian Safety Chucks are built to perform.

TSC Torque Sensing Control System

The latest innovation in tension control brings near closed loop levels of accuracy and precision to open loop/diameter based tension control systems. Featuring the patent pending Torque Sensing Brakes, the TSC System is an all in one total package delivering increased product quality, reduced scrap, and increased productivity.

February 2015 Better Web Control Newsletter

In this issue:
ICE USA & Europe Preview

Montalvo to Debut All New Tension Controller, Safety Chucks & Open Loop Control System at ICE 2015
Z4 Tension Controller – Guardian Safety Chucks – TSC Control System

Over the past year we have been working hard at developing some real industry game changers and a set to debut three entirely new product lines along with our lineup of load cells, brakes, controllers, sensors and more at ICE USA 2015 & ICE Europe 2015.

ICE USA: Booth #511
ICE Europe: Hall A6, Stand 481

We will be showcasing our latest advanced tension controller, the Z4, along with our new line of patent pending Guardian Safety Chucks, and a new Open Loop Tension Control System featuring the patent pending TSB Torque Sensing Brakes.

The Z4, Guardian Chucks and TSC System offer a variety of new functions, features, and patent pend technology that the industry just hasn’t seen before, and will truly improve the capabilities of existing an new machines.

In today’s competitive landscape every advantage matters and these products deliver.

Detailed Product Information:

Z4 Tension Controller

Processes: Unwind, Intermediate/Nip, Rewind, Differential Rewind
Feedback: Load Cell, Dancer, or Both
Functionality: Soft Start, Anti Coast, Splice, Taper, Inertia Compensation, Web Break Detection, Remote Setpoint, Remote Tension On/Off, Progressive Gain, Trim Adjust, Variable Wrap, Range Expansion, Dual Calibration
7″ HD Display Screen
110-240VAC and 24VDC versions
Process Trend Storage
User Defined Units & Scaling
Remote Installation (Z4r)
Upgradeable Communications
Ethernet (Q1 2015)
Multi Lingual HMI
Two Mounting Options (Z4e): Panel or Surface
Compatible with Pneumatic or Electric Brakes & Clutches
Compatible with Drives
Analog & Digital Hybrid
Automated Shaft Fill
Compatible with a Range of Feedback Sources: Ultra-Sonic Sensors, Dancer Position Sensors, Proximity Sensors, Laser Sensors, and Potentiometers.
Tension Indication
Multiple Mounting Options
Set It & Forget It Technology

Guardian Safety Chucks

Redesigned Handwheel & Journal Seat Replaceable Handwheel Inserts – no longer a need to replace worn handwheels Reversible Safety Lock (optional)
Available Worldwide
Automatic Locking
Rugged, Hardened Design
Pedestal Mount or Flange Mount Options High Speed
Superior Concentricity

TSC Torque Sensing Control System

Customizable System Packages
- Pick and choose TSC system components based on the needs of your application to creat your total tension control solution.
TSC Components
- V or CS Series Torque Sensing Brake with TS1 Torque Sensor
- U4 Open Loop/Diameter Tension Controller
- US4 Ultrasonic Sensor or Proximity Sensors IP Converter
Easy Installation, Set Up & Operation
- Save time with quick and easy installation and set up, while still providing simple to use operation.
Reduces Machine Build Cost
- The TSC system eliminates the need for additional rollers and load cells while still providing precise, consistent tension control.
Easily Upgrade Existing Machines
- Upgrade the capabilities of your machine. The TSC system easily integrates into existing machines, while working with existing components, allowing you to select only the specific new TSC components you need.
The U4 – Advanced, Fully Featured Tension Controller
- Featuring soft start, anti-coast, taper tension, 0-10V or 4-20mA versions, programmable diameter alarms, the ability to save up to 9 different tension process parameters, and more.
Smooth, Precise, Repeatable Tension Control from Full Roll to Core
- Montalvo’s performance driven V and CS series tension brakes feature industry leading linear torque delivery, wide torque ranges, high heat dissipation, high quality construction, and reduced maintenance time.
Compact & Space Saving Tension Control Package
Performance Driven, High Quality Components

January 2015 Better Web Control Newsletter

In this issue:
Kick Off 2015
XR Pulley Load Cells
Web Guides

Kick Off 2015 with Increased Productivity Tension Control Upgrade Packages

In today’s competitive marketplace, manufacturer’s commonly are required to do more with less. A Montalvo tension control upgrade package can deliver a cost effective, immediate return on investment that allows existing machines to effectively compete with today’s new machines.

We work with you to find the best solutions to meet your budget and production goals. Make 2015 one your best yet with Montalvo.

Experience
With our 67 years of experience in the tension control industry, you know you are getting the best in knowledge and experience to make your application more productive.

Drop In Replacements
Whether you’re upgrading our components or other manufacturers, a majority of our upgrades easily integrate into your current application.

Cost Effective
We specialize in cost effective upgrades that deliver a quick return on investment and increase your productivity years to come.

Support
We pride ourselves on our ongoing after sales service and support for all of our customers. We are here for you!

Increases Your Capabilities
A few key, simple changes will make your machine run as practically new, enhancing the capability, productivity and profitability of your application.

Get a Free Upgrade Consultation
See more of Montalvo’s Upgrades and Retrofits

XR Series Pulley Load Cells
Designed for single strand applications – wire, filament, cable, etc

Part of our X series of load cells the XR is a fully customizable load cell to meet the specific needs of your single strand application.

The XR pulleys are built to suit or are capable of accepting your existing pulleys for the ultimate in cost effective and simple integration into your process.

Additional features include:

100% Stainless Steel Body
Industry Leading Sensitivity
Mechanical Variance Compensation
360° Overload Protection
Multiple Mounting Options

Visit our XR webpage for more information

Web Guides from Coast Controls Total tension control equipment packages

Montalvo and Coast Controls have created a new strategic partnership designed to provide our customers comp tension control and web guiding equipment packages.

As a preferred supplier to Coast Controls, Montalvo tension control equipment, including controls, load cells, bra and sensors will be featured on Coasts’ new machine builds and retrofit applications.

In addition, Coast Controls Web Guides are now available for direct sales, service, and support through Montalv and Montalvo Representatives in select regions.

Coast Controls All Air Web Guiding Systems are simple to install, simple to operate, are highly cost effective an have a longer service life.

Visit our Coast Controls Web Guide page for more information

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Better Web Control Newsletter - December 2015

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