Coating & Laminating
The critical role of tension control in coating and laminating processes
I
n any coating or laminating process, tension control plays a critical role in achieving consistent product quality. Whether working with films, foils, papers, or specialist substrates, maintaining stable web tension throughout the process ensures that materials run smoothly through the machine without stretching, wrinkling, or misaligning. Poor tension control can lead to coating defects, registration issues, inconsistent laminate bonds and ultimately increased waste and downtime.
Good tension control is about precision and stability. Modern coating and laminating lines rely on carefully designed unwind, web handling and rewind systems to keep the material under the correct tension at every stage of the process. Too much tension can deform delicate substrates or cause necking, while too little tension can result in slack web conditions, wrinkles, and poor coating uniformity. For converters working with increasingly thin, sensitive, or high- value materials, this level of control is more important than ever.
A key technology that supports this level of accuracy is the closed-loop tension control system. In a closed loop setup, sensors such as load cells continuously measure the web tension in real time. This data is fed back to the control system, which automatically adjusts drive speeds and braking torque to maintain the desired tension setpoint. Because the system is constantly monitoring and correcting tension variations, it provides a far more stable and responsive process than traditional open- loop methods. This is particularly valuable in coating and laminating applications where coating weights, adhesive performance and product quality can all be affected by even small changes in web tension.
Build quality also plays a significant role. A well engineered machine with rigid frames, precision rollers and responsive drive systems provides the mechanical stability required to maintain accurate tension profiles. Combined with advanced control systems, operators can manage tension across different zones of the
The team at Universal Converting Equipment works closely with its sister company, Universal Adhesive Systems, bringing together expertise in both web handling and hot melt adhesive technology. This collaboration allows the companies to develop equipment that considers the entire coating and laminating process, from substrate handling to adhesive application. As Alan Jones, Managing Director of both businesses, explains:
machine, ensuring consistent performance from the unwind through to the rewind. Of course, every converting process is diff erent. Substrate type, coating chemistry, line speed, web width and fi nal product requirements all infl uence how a machine should be designed. There is no “one size fi ts all” solution. Instead, coating and laminating equipment must be engineered to meet the specifi c needs of the product and the process it supports.
“We have been combining experience from both the converting and hot melt adhesive industries for many years. In 2024 we brought both companies under the same roof and the combined knowledge and output is proving invaluable for our customers.”
By combining engineering expertise with deep process knowledge, the partnership is able to deliver tailored solutions that help converters achieve consistent quality, improved efficiency and greater process reliability. In an industry where precision matters at every stage, effective tension control remains one of the foundations of successful coating and laminating operations.
14
March 2026
www.convertermag.com
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