Accumulators

Our accumulation systems perform a number of functions. The most important function is material buffering, where the system temporarily stores a certain number of metres of web material. Typically, the fabric accumulator is used after unwinding and before rewinding systems.

During the roll change at the beginning or end of a production line, the accumulator is emptied or filled. The accumulator is filled or emptied by means of pull units located on the infeed and outfeed sides. A web tension control system positioned between the pull units allows continuous web tension in the accumulator by means of dancer position control or an alternative measuring roller. This allows a continuous process between the accumulators without interruptions and speed fluctuations.

This approach offers several production benefits. The important core processes, such as coating or laminating, are decoupled from the winding processes within the production. The winding processes at either end of the system run independently of the rest of the production line. Different speeds within the winding processes are no problem. The required storage capacity or the length of material in the accumulator can be customised.

A accumulator compensates for possible fluctuations in the supply and removal of material to the main process. Even necessary downtime of the unwind and rewind processes during reel changes is not a problem. In such cases, the accumulator provides sufficient material from its storage ahead of the core process. Conversely, the accumulator refills after the core process. This ensures that there is always a continuous flow of material in this important production process.

Depending on the properties of the material and the desired material handling, different types of accumulation systems can be used. In addition to roller accumulation systems, the simplest option for a material storage system is a J-Box accumulation system. In this type of accumulation system, the web material is fed into a J-shaped trough by means of a pulling device. The weight of the material causes it to be deposited in folds in the trough. The material is removed from the accumulator by a pull unit and fed to the next process.
Tension control by means of a dancer position control or measuring roller provides the possibility of controlled web tension. A spreading systems positioned in the pull-off area allow the folded material to be fed to the next process with the maximum stretched width.

The material properties of the roll surface or trough can be taken into account depending on the specific material properties of the web material and its application (wet or dry). The storage of the guidance rolls in the accumulator can also be adapted to the possible tensile sensitivity of the material.
Belt accumulators are used as an alternative to roller or J-Box accumulators. The web is fed onto a conveyor belt that runs horizontally at a reduced speed. The material is deposited in a folded form. The storage capacity depends on the length of the conveyor belt and the process speeds.

A key feature of a fabric accumulator is its use for storing web-like materials. Films, wovens, non-wovens, carpets, technical textiles, paper and more are stored in the accumulator to ensure a continuous production process during roll changes. The capacity of such a system is designed according to the customer’s requirements. Depending on the time required for a roll change and the maximum production speed, the required length of material to be stored is calculated. Restrictive site conditions can affect the height and resulting length of a accumulation system. Each accumulation system is therefore designed and manufactured to meet the customer’s requirements. Electrical control of the accumulation systems is by PLC or alternative systems as required by the customer.

A major advantage of a fabric accumulator is its simplicity of design and application. Time-consuming manual roll changes during unwinding and rewinding can be avoided with accumulator systems. With the roller accumulator, the web material can be easily threaded between the travelling and stationary roller arrangements by means of an intermeshing roller arrangement.
In addition, easy access to the accumulator via the guards allows easy handling of the web. Good accessibility is also helpful for maintenance.

A fabric accumulator also contributes to better quality in continuous production processes. Tension fluctuations in the web guide of the material can be reduced and the priority production process is stabilised. An uninterrupted production process enables consistent product quality.

Do you have special requirements for buffering your web materials? We can develop and implement the material accumulation concept you require. Depending on the characteristics of the material, we can offer you various accumulation solutions specifically for your application.

With Krögel Maschinenbau at your side, the path to advanced, customised accumulators is open to you. Contact us to realise your production goals. Our experts are ready to work with you to develop the optimum solution for your requirements.