Development of an Industrial Roll Rewinding and Perforating Machine

Project overview

CUSTOM INDUSTRIAL EQUIPMENT FOR ROLL PROCESSING

Industrial roll-processing equipment must combine reliable material handling, precise cutting and perforation, production speed, and efficient use of factory space.

KVAZAR was commissioned to develop a custom machine for rewinding and perforating roll materials according to a demanding set of technical requirements.

THE CUSTOMER'S REQUIREMENTS

The machine needed to be compact enough for installation on upper floors of a production facility, with a total weight not exceeding the project's structural and installation constraints.

The specified rewinding speed was 80 m/min, while electrical power consumption had to remain below 3 kW using a single-phase power supply.

The machine also needed to support material rolls up to 1,200 mm in diameter, perforate fabrics with a basis weight starting from 15 g/m², and perform cutting using circular disc knives.

Additional requirements included a noise level not exceeding 85 dB, belt-driven mechanisms for precision operation, and operator protection.

MECHANICAL ENGINEERING AND DEVELOPMENT

The development focused on combining the rewinding, perforation, and cutting mechanisms within a compact machine structure.

Belt-driven systems were incorporated in accordance with the customer's precision requirements. The machine also included a perforation system for lightweight materials and a cutting mechanism using circular disc knives.

The overall layout was developed to accommodate large-diameter rolls while controlling the machine's dimensions, weight, and electrical consumption.

MANUFACTURING AND RESULTS

Following development and manufacturing, the completed machine met the customer's requirements.

The resulting dimensions were 1,550 × 2,200 × 1,700 mm, with a machine weight not exceeding 1,700 kg.

More importantly, the equipment exceeded the original performance targets. Rewinding speed reached 120 m/min instead of the required 80 m/min, representing a 50% increase over the specification.

Electrical power consumption was reduced to 2.3 kW, compared with the original maximum of 3 kW.

ENGINEERING CAPABILITIES

This project demonstrates KVAZAR's capabilities in custom industrial machinery development, mechanical design, roll-handling systems, perforation and cutting mechanisms, and equipment optimization under strict installation and energy constraints.

The challenge

Develop and manufacture an industrial machine for rewinding and perforating roll materials according to specific production requirements. The equipment had to combine compact dimensions, low noise, precise operation, single-phase electrical power, operator protection, and the ability to process materials with a basis weight starting from 15 g/m². The specified rewinding speed was 80 m/min, with power consumption not exceeding 3 kW.

Constraints

The machine had to meet several engineering constraints simultaneously:

• Compact dimensions suitable for installation on upper floors of a production facility.
• Noise level not exceeding 85 dB.
• Belt-driven mechanisms for precise operation.
• Single-phase power consumption not exceeding 3 kW.
• Perforation of fabrics with a basis weight starting from 15 g/m².
• Minimum rewinding speed of 80 m/min.
• Operator protection during operation.
• Compatibility with material rolls up to 1,200 mm in diameter.
• Cutting performed using circular disc knives.

The principal engineering challenge was integrating these requirements into a compact, stable, and energy-efficient machine.

Our solution

KVAZAR developed and manufactured a custom roll rewinding and perforating machine designed around the customer's production constraints.

The mechanical design incorporated belt-driven mechanisms, a perforation system for lightweight materials, disc-knife cutting, and provisions for operator protection.

The machine was engineered to accommodate rolls up to 1,200 mm in diameter while maintaining compact overall dimensions and limiting electrical power consumption.

The resulting design achieved a higher rewinding speed and lower power consumption than originally specified.

Implementation

1. Analysis of the customer's technical requirements and installation constraints.
2. Development of the machine layout and mechanical concept.
3. Design of the rewinding system using belt-driven mechanisms.
4. Engineering of the perforation system for materials starting from 15 g/m².
5. Integration of disc-knife cutting mechanisms.
6. Development of the machine structure and operator protection provisions.
7. Preparation of engineering documentation.
8. Manufacturing and assembly of the machine.
9. Evaluation of the completed equipment against the customer's requirements.

Technical details

Equipment: Industrial roll rewinding and perforating machine

Dimensions (L × W × H): 1,550 × 2,200 × 1,700 mm
Machine weight: Not exceeding 1,700 kg
Achieved rewinding speed: 120 m/min
Required rewinding speed: 80 m/min
Achieved power consumption: 2.3 kW
Maximum specified power consumption: 3 kW
Power supply requirement: Single-phase
Noise requirement: Not exceeding 85 dB
Supported roll diameter: Up to 1,200 mm
Material basis weight: From 15 g/m²
Drive system: Belt drives
Cutting system: Circular disc knives
Additional requirements: Perforation system and operator protection

The result

The completed machine met the customer's specified technical requirements while exceeding two key performance targets.

Rewinding speed increased from the required 80 m/min to 120 m/min — a 50% improvement over the specification.

Power consumption was reduced from the maximum permitted 3 kW to 2.3 kW, approximately 23% below the specified limit.

The machine maintained compact dimensions of 1,550 × 2,200 × 1,700 mm and a weight not exceeding 1,700 kg.

The project demonstrates the successful integration of mechanical performance, compact equipment design, and energy efficiency.

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