Custom converting equipment is the machinery that feeds, controls and finishes material around the weld: unwinds that feed fabric under tension, accumulators that keep it moving, cutters and grommeting units that finish it, and folders and rewinds that package it. Miller Weldmaster builds this equipment into automated welding lines, such as the Moduline, which unwinds, welds and rewinds on one machine, and also supplies stand-alone converting machines such as the GRW2400 rewind and the ultrasonic cutter. Each system is configured around your product, material and production volume.
Key Takeaways on Custom Converting Equipment
Unwind to Rewind on One Line
A Moduline system unwinds, welds and rewinds on one machine, creating large rolls in a reduced workspace with less handling between steps.
Steady Tension and Tracking
Unwinds with automatic tension control, edge sensing and fabric edge guides keep material feeding smoothly and welding parameters accurate.
Finishing Built In
Cut-to-length, in-line grommeting and automated folding finish the product on the line, so it comes off cut, grommeted, folded or rolled.
Built to Your Product
Modular designs in any width, upper and lower welding heads and custom specifications let each system match your product, material and volume.
How Converting Equipment Fits Into a Welding Line
In an automated line, converting equipment handles every step before and after the weld. Unwinds feed one or more rolls of fabric under controlled tension. An accumulator stores a short length of material so the line keeps moving while a slower step, such as grommeting, finishes its work. Welding heads join the panels, then cut-to-length units, grommeting systems and folders finish the product, and a rewind rolls it up for storage or shipment. On the HG50 banner machine, for example, precision unwinds and a fabric edge guide feed the material, a built-in accumulator regulates its flow into the grommeting stage, and a bi-directional cutter finishes each banner, so one operator can run the whole process. For a broader look at equipment types, features and maintenance, read our complete guide to converting equipment.
コンバーティング機器の種類
巻き戻し
Unwinds feed fabric into the line under controlled tension. On the Moduline, unwinds provide automatic fabric tension control; the M100 Multiple Roll pairs fabric unwinds with keder unwinds to reduce material handling, and its edge-sensing design keeps welding parameters accurate. Multiple unwinds let one line weld several rolls together into one large product.
Rewinds
Rewinds roll the finished product up for storage or shipment. The Moduline’s precision-controlled rewinds reduce fabric handling, and the M100 Folding’s tensioned rewind produces customer-presentable rolls. For very large liners, the stand-alone GRW2400 rewind handles rolls of up to 10,000 lb (4.53 t), pulling any length of liner from the floor onto the roll with a powered drive, tension rollers and pneumatic disc braking that fits more material on each roll.
Cut-to-Length and Finishing
Finishing equipment completes the product on the line. Cut-to-length units on the Moduline and M100 cut each product to an accurate size, and filter tube and bag systems can cut straight or radius lengths. In-line grommeting places reinforced grommets automatically; on the HG50, photo eyes position plastic or metal grommets before a bi-directional cutter finishes the banner. As a stand-alone tool, the ultrasonic cutter cuts and seals fabric edges cleanly, with no fraying, burning or smoke.
アキュムレーター
Accumulators store a length of material between steps so the line keeps running when one step is slower than another. On the HG50, the built-in accumulator regulates the flow of material into the grommeting stage and keeps the machine and banner moving consistently. Miller Weldmaster also builds multi-panel accumulator welders for geomembranes, and filter tube and bag systems can be automated with accumulators.
Folding Systems
Folding systems fold large products as they are welded. The M100 Folding welds and folds large products in half, giving a compact product that reduces in-field installation labor, with multiple frame designs for different fold requirements and an automated folding system for hands-free operation. It is built for agricultural curtains and geomembrane liners.
加工機械アプリケーション
Miller Weldmaster’s converting systems are built for large welded fabric products that start as rolls and leave as finished goods:
- Geomembrane liners and covers, containment booms and roofing membranes
- Tents, clear span buildings, greenhouses, pergolas, shades and shelters
- タープとカバー
- Agricultural curtains
- Banners and billboards
- Filter tubes and bags
- Spiral and flexible ducting
- Pool covers and liners
- Awnings, blinds and marine products
- Irrigation products
Miller Weldmaster Converting Systems
The Moduline is a fully automated multi-roll system that unwinds, welds and rewinds on one machine, with modular widths, upper and/or lower welding heads, cut-to-length, in-line grommeting, a modular catwalk for seam inspection and PLC recipe storage. The M100 Multiple Roll welds multiple rolls with multiple hot air heads, keder unwinds and cut-to-length for tents and structures. The M100 Folding welds and folds large products in half and rewinds them under tension.
Stand-Alone Converting Equipment
Not every shop needs a full line. The GRW2400 rewind rolls finished liners of up to 10,000 lb for shipment and significantly reduces the manpower needed to rewind them. The ultrasonic cutter cuts and seals fabric for awnings, blinds, marine products and shades, with low energy use, no warm-up time and auto-tuning for different materials.
Benefits of Custom Converting Equipment
Converting equipment built around your product means less handling between steps, fewer people needed to move and roll heavy material, products that leave the line finished and rolled for your customer, and folded products that take less labor to install in the field.
Installation, Training and Support
Every converting system comes with Miller Weldmaster’s three-step training process. A certified field service engineer schedules installation and training at your facility, Miller Weldmaster gives your team everything it needs to prepare, and your staff receive extensive instruction on operating and maintaining the equipment and producing your product. After installation, the Service & Resolution Center supports your team, and each machine page includes overview and training videos.
カスタムコンバーティング機器にMiller Weldmaster を選ぶ理由
Miller Weldmaster designs the welding and the converting equipment together, so unwinds, accumulators, welding heads, cutters, folders and rewinds are built to work as one line. Each system is built to your specifications in any width, with the welding method your material needs, from hot air and hot wedge to impulse, radio frequency and sewing. Miller Weldmaster is headquartered in Navarre, Ohio, with a European office in Nieuw-Vennep, the Netherlands, and its team guides you through the buying process from the first conversation to installation.
Frequently Asked Questions About Custom Converting Equipment
What is custom converting equipment?
Machinery that feeds, controls and finishes material around the weld, such as unwinds, accumulators, cut-to-length units, grommeting systems, folders and rewinds. Miller Weldmaster builds it into automated welding lines or supplies it as stand-alone machines.
What converting equipment does Miller Weldmaster make?
Multi-roll systems such as the Moduline and M100 Multiple Roll, the M100 Folding, the GRW2400 rewind for liners up to 10,000 lb, the ultrasonic cutter, and unwinds, accumulators, cut-to-length and grommeting built into automated lines such as the HG50.
What does an accumulator do in a welding line?
It stores a length of material between steps so the line keeps moving when one step is slower than another. On the HG50, the accumulator regulates the flow of material into the grommeting stage.
What products are made with converting equipment?
Geomembrane liners and covers, tents and structures, tarps and covers, agricultural curtains, banners and billboards, filter tubes and bags, ducting, pool covers, awnings and other large welded fabric products.
Does Miller Weldmaster install converting equipment and train operators?
Yes. A certified field service engineer schedules installation and training at your facility, and your staff learn to operate and maintain the equipment and produce your product.
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