What is Tension Control?
Tension control is the ability to maintain consistent and accurate tensile force on a product for repeatable defect free processing.

To control a continuous length of web, cable, or wire along a machine requires the product to be kept “in tension” to manage and keep elongation as constant as possible.

Tension control also keeps the product aligned and tracking properly which helps to eliminate defects such as scratches, wrinkles, breaks as well as registration and rewind defects.

Either for designing new equipment or for upgrading an existing machine, the final success expected from the tension control system relies heavily on the process analysis. Accurate data and experienced analysis will lead to the very best component selection.

What are the benefits of a Tension Control system?
A properly calibrated tension control system allows manufacturers to operate consistently and efficiently. In turn, this means faster production with reduced waste in time and materials.

What are the different types of Tension Control?
The different types of tension control consist of web tension control, wire-cable tension control, pre-stretch tension control, and intermediate tension control. Different industries and applications require different kinds of tension control systems.

Web Tension Control
Web tension control provides the required web traction and stretch. Web tension control is used within many industries including: Converting, Printing, laminating, Labeling, Nonwovens and Inspection.

Wire-Cable Tension Control
Wire-cable tension control is used to reduce breakage and control stretch. Wire-cable tension control systems are often used in: Taping/Coating, Braiding, Reeling and de reeling, Payoffs, Annealing and thermal processing, Reel and flyer and Creel unwinding.

Pre-Stretch Tension Control
Pre-stretch tension control is an application that allows film, plastic and other materials to be stretched before being applied to a given substrate. Pre-stretch tension control is used within the printing, labeling, and converting industry.

Andantex USA has several products listed below that support this process.

Intermediate Tension Control
Intermediate tension control is an application that supports the intermediate process zones, which require unique tension values. Applying a slight difference of linear speed between the infeed and draw station pulls on the web. The differential gearboxes provide adjustment of the speed difference allows to adjust the speed difference with the highest accuracy and then controls the web tension on each printing station. Intermediate tension control is used within the printing and converting industry.

How does a tension control system work?
A tension control system works by applying a controlled torque to the unwind shaft, a capstan, or nip rollers.

What is the difference between open-loop and closed-loop tension control?
The difference between open-loop and closed-loop tension control is that closed-loop tension control introduces real-time tension measurement combined with automated adjustments to achieve and maintain the tension setpoint. Open-loop systems can vary the tension but there is no direct measure of the tension. The products used for open-loop tension control are typically diameter measure and power supply or digital controllers. The products used for closed-loop tension control are load cells or dancer arms with a digital PID controller.

How to calculate Tension Control?
Tension control components are sized based on specific calculations using the information provided by the end-user. Andantex can size the components for free. We ask that you contact us for assistance.

What are the components of a Tension Control system?
The typical components of a tension control system are the brake or clutch, sensor, and digital controller.

Which industries would use Tension Control?
The industries that use tension control are the converting, labeling, wire & cable, and packaging industries.

What problems does Tension Control solve?
The proper tension control system eliminates the following issues within product manufacturing or production industries: Material wrinkles, Breaks in production/processes, Inconsistent material coatings, Inconsistent cutting of properties/dimensions, Mis-printing on paper or material, Print jamming, Web guiding, Scratches, Telescoping, Dishing and Rough edges.

What support does Andantex offer for these types of systems?
Free system calculations
Cad drawings
Solid Models