Better Web Control Newsletter - July 2014

In this issue:
Product Spotlight: V Brake & V Pad
North American Sales Team
The new Montalvo.com

Built to define Productivity!
Increase the performance of your application while minimizing maintenance

From bolt to disc to pad, the V-Brake is designed to increase your productivity. No other brake in the industry is as easy to install, operate, and maintain as the V-Brake.

Maintaining your V-Brake takes only seconds with Montalvo’s exclusive “snap-out, snap-in” brake pad changes. Performance & Productivity in perfect unison.

Features include:

• Wide Torque Range
• Increased Cooling Capacity
• High Heat Dissipation & Thermal Capacity Discs Easy Installation
• Minimal and Easy Maintenance
• Bi-Directional Operation
• Immediately Operational

Learn More

Montalvo Cements its North American Sales Team
New inside sales, applications specialists and expanded territories.

We have finished the final steps in reorganizing our North American Applications Team with expanded territories of several of our representatives, the addition of two new regional sales managers, and a new inside sales & support specialists. Montalvo’s Applications Team members assist customers with all aspects of technical sales, tension control consultation, product service and support.

Chief Operating Officer Robin Goodwin says “We wanted to create the strongest possible team for our North American market. We expanded the territories of several of our current representatives. In addition, we saw a number of benefits in going direct in our Northeast and Southeast markets. This not only gives our representatives greater opportunities but ensures our customers are getting the very best in terms of service and support. By using a hybrid approach to our North American team, we leverage the combination of so of the strongest representatives in the industry, excellent technical sales and direct sales. I am very excited abo our team going forward and confident in their ability to drive growth in the years ahead.”

Read the Press Release

The re-designed Montalvo.com
Quicker navigation, enhanced user experience, new layout and more!

New Benefits Include:

• Drop down navigation to get to pages quicker
• Highlight of Upgrades and Retrofits
• Password Protected Logins
• Saved Login Sessions to reduce login frequency
• Dedicated multi-lingual versions of the site (coming soon)
• More informative and easier to navigate product pages
• Enhanced usability for Local Contacts pages
• Responsive design for mobile and tablet devices
• Fresh, new design
• and more

Visit the NEW Montalvo.com

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

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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.

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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

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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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In This Issue:
Introducing the re-designed Montalvo.com

Introducing the re-designed Montalvo.com
Quicker navigation, enhanced user experience, new layout and more!

We are proud to announce the launch of the NEW montalvo.com! The new montalvo.com brings a variety of new features and benefits while paving the way for even further enhancements to ensure you are always able to find the information you are looking for.

New Benefits Include:

• Drop down navigation to get to pages quicker
• Highlight of Upgrades and Retrofits
• Password Protected Logins
• Saved Login Sessions to reduce login frequency
• Dedicated multi-lingual versions of the site (coming soon)
• More informative and easier to navigate product pages
• Enhanced usability for Local Contacts pages
• Responsive design for mobile and tablet devices
• Fresh, new design
• and more

The re-designed website reflects Montalvo’s commitment to modern design, performance, and quality across everything we do. Better products, better support, better service, for Better Web Control!

Visit the NEW Montalvo.com

In This Issue:
Better to be Proactive than Reactive!
X Series Cantilever or Pulley Load Cells
Tension Control Delivered to you in 1-2 weeks

Better to be Proactive than Reactive!
Proactive maintenance & service can prevent costly downtime.

We are here for you! Montalvo Field Services can ensure your machines and equipment are in proper working order and spot potential problems before they occur.

Being proactive can often be the difference between profit and loss.
Montalvo offer’s a variety of different Field Service options to best meet the needs of your specific application and production.

View Field Services and Product Training

X Series Cantilever or Pulley Load Cells
Built to meet the needs of your application

X Series Load Cells are designed for applications utilizing either cantilevered rollers for narrow webs or pulleys for wire, filaments and other single strand webs.

Custom specify your roller or pulley, or X Series Load Cells can also support your existing rollers or pulleys for easily integrating high quality tension sensing to your application.

Custom roller options, two mounting styles and Montalvo’s renown Extra Sensitive load cell technology make the X a perfect choice for the narrowest of webs.

Check out the X Series

Tension Control Delivered to you in 1-2 weeks
Tension Controller, Load Cells, Amplifier

Achieve more – Industry leading tension control products delivered to you in 1 week (*2 weeks for regions outside North America)

Increase the capabilities of your machine with a few key simple upgrades today! Contact a Montalvo Applications Specialist to learn more.

> More on the S4 Digital Tension Controller
> More on the ES Dead Shaft Idler Load Cells
> More on the M-3200 Amplifier

In This Issue:
Montalvo Expands Sales & Engineering Teams
In Line Tensioner for Tube Manufacturing
Custom Engineered Tension Control Solutions

Montalvo Expands Sales & Engineering Teams
New VP of Engineering, Software Engineer, Regional Sales Managers and Inside Sales

With a focus on always providing our customers the very best in customer service, support, and innovative and performance driven products we are proud to announce our newest and promoted team members.

• Jon Hanson – Vice President of Engineering
• Ted Dufour – Software Engineer
• Tony Rossetti – Northeast Regional Sales Manager.
• Dave Mareiniss – Southeast Regional Sales Manager
• Steve Larrivee – Inside Sales & Support

For more information please contact us

In Line Tensioner for Tube Manufacturing
New custom engineered solution

Designed for to create a tension control zone prior to specific processing, where none previously existed Montalvo had designed a new in line tensioner as a drop in solution.

The custom in-line tensioner utilizes a CD Series Brake, i4 Tension Indicator and a pair of ES-LR Live Roller Load Cells. Operators are able to manually adjust output to the brake to create the exact desired tension level based on the precise tension feedback provided from the load cells displayed on the indicator, eliminating the guesswork in adjusting tension by touching the web.  An automatic version utilizing the S4 Closed Loop Tension Controller is also available.

Read the full release

Custom Engineered Tension Control Solutions
Unique problems require unique solutions

Sometimes the answer to your tension control problems isn’t already available for you. We have engineered hundreds of unique web tension control products and product modifications to give our customers the edge they need to make their application more efficient, more productive, and more profitable.

If you have a unique tension control problem, contact a Montalvo Applications Specialist to start discussing possible solutions.

> View some examples of our custom engineered solutions

> Talk to an Applications Specialist

In This Issue:
New Video: U Series Load Cell Installation & Calibration
Product Spotlight: Under Pillow Block Load Cells
Tension Control Delivered to you in 1-2 weeks

New Video: U Series Load Cell Installation & Calibration
See just how easy it is

In this new video we showcase the in’s and out’s of  installing and calibrating your U Series Load Cells. U  series load cells are custom drilled and tapped to your  bearing specifications ensuring they arrive ready for a  simple installation.

Check out the video to see how easy it is, or get assistance with installing your own U Series Load Cells

View the video

Product Spotlight: Under Pillow Block Load Cells
Superior tension control starts with a superior tension signal

Designed for use under pillow block bearings, the U Series industrial construction provides an accurate and repeatable signal even in harsh environments.

U Series Load Cells are IP67 rated, chemical and corrosion resistant and feature easy 4 bolt mounting, providing you the performance and service life you require with a hassle free installation process.

Additional features include:

• Semiconductor Strain Gauge
• Overload Protection
• Full Scale Linear Output
• Custom Drilled & Tapped for your bearings

See it all

Tension Control Delivered to you in 1-2 weeks
Tension Controller, Load Cells, Amplifier

Achieve more – Industry leading tension control products delivered to you in 1 week (*2 weeks for regions outside North America)

Increase the capabilities of your machine with a few key simple upgrades today! Contact a Montalvo Applications Specialist to learn more.

> More on the S4 Digital Tension Controller
> More on the ES Dead Shaft Idler Load Cells
> More on the M-3200 Amplifier

In This Issue:
The Importance of Load Cells
Video: Load Cell Sensitivity and Resolution
Tension Control Delivered to you in 1-2 weeks

The Importance of Load Cells
A look into this vital component of quality tension control

Excerpt – “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.”

Read the entire article

Load Cell Sensitivity and Resolution
Superior tension control starts with a superior tension signal

Take a more detailed look into two of the most important factors in selecting an ideal load cell for your application. Superior tension control is dependent on a superior tension signal so your controller is accounting for even the slightest changes in tension. This ensures maximum productivity and higher quality end products.

Here we feature a video walk through of these two aspects of load cells, as well as provide testing data and more on our very own load cells.

See it all

Tension Control Delivered to you in 1-2 weeks
Tension Controller, Load Cells, Amplifier

Achieve more – Industry leading tension control products delivered to you in 1 week (*2 weeks for regions outside North America)
Increase the capabilities of your machine with a few key simple upgrades today! Contact a Montalvo Applications Specialist to learn more.

> More on the S4 Digital Tension Controller
> More on the ES Dead Shaft Idler Load Cells
> More on the M-3200 Amplifier