Flexible production line for technical textiles: Condako Engineering case

A strong partnership driving innovation

Condako Engineering↗, a specialized supplier to the automotive industry, focuses on developing and producing specialized foils and membranes (non-wovens), customized for specific client applications. This emphasis on custom work requires a production environment that can smoothly switch between various materials and processes. However, their existing production line no longer met these demands sufficiently enough.

“Over the years, we had invested in several stand-alone production machines, each performing their task. We recently also invested in a hot melt coating machine. So, we started thinking of integrating these machines in a flexible full process line. Furthermore, our laminating line was no longer suitable for the broad spectrum of materials we want to process today,” says Michael Boeren, product and process manager of Condako Engineering. “It was far too slow, offered no adequate tension control, and had poor cutting quality. Moreover, we couldn’t perform certain processes independently. If we wanted to slit, we couldn’t laminate.”

To resolve these bottlenecks and increase production capacity, Condako invested in two projects. The first was a new, modular rewinding line where an existing perforating machine and laminating machine were integrated in a flexible finishing line, and a flying cross cutter to place after the lamination machine. Both projects were developed together with Handsaeme Machinery. These investments proved to be a crucial step forward to increase capacity and flexibility.

Speed, precision, and modularity

The new Flexline from Handsaeme Machinery combines unwinding, slitting, and rewinding. Its true strength lies in its modular design, which enables the integration of the existing machines which allow perforation, corona treating (the static charging of surface material) and lamination in various sequences.

“The speed of unwinding and rewinding is crucial. Where our old line maxed out at 25 meters per minute, the new line reaches up to 100 meters per minute. With this line, we can combine different processes into a single production flow and still remain extremely flexible. Sometimes all the integrated machines are used, sometimes none, and the order in which they operate can be easily adapted to the product requirements.” — Michael Boeren

One of the biggest technical challenges was the enormous variety of materials. “Between the lightest and heaviest material, there is a huge multiple in grammage,” says Boeren. “Foils can start from 20-micron thickness, and membranes can add up to 200 grams, even higher if needle-punched. If you apply too much tension to a light product, it will stretch or neck down. Perfect tension control is therefore essential and different for each product. The new production line handles this flawlessly.”

An innovative solution was also chosen for cutting: a combination of shear cut and fixed blades, allowing the customer to choose the best cutting method for each material.

In addition to the rewinding line, Condako also implemented a flying cross cutter from Handsaeme behind a standard Reliance double belt laminator. Previously this was only used for flexible materials in a roll to roll process, now we also process rigid composite sheet materials on it (a new product offering by Condako). This machine cuts the continuous laminated composite panels on-the-fly, without needing to slow down or stop the production line. A unique thickness detection system recognizes the transition between the core sheets of the laminated materials, ensuring an extremely precise cut and optimizing material waste.

From supplier to development partner

The collaboration with Handsaeme was exceptionally smooth. “We’ve had very good contact with Jonas, who was our SPOC in the development phase and is not only a commercial representative, but also has a great technical background. But another big advantage was having direct contact with the programmers after the installation,” says Boeren. “During the start-up phase, parameters of the PLC could be adjusted quickly without needing intermediate steps or going too much back and forth. That sped up the implementation enormously.”

Thanks to these new investments, Condako now has a faster, more flexible, and more precise production environment, perfectly suitable for developing new products together with its clients.

Because in the end, it’s not just about the material — it’s about controlling the process around it.

➡ Want to read more success stories?

Discover how other companies benefit from our solutions on our References page.