1. Tension Control Upgrade
Mark Andy
Tension Control Upgrade
Featuring MA2200 and MA4120 Presses

2. MA Press Upgrade
Overview
In order to compete with today’s new machines, older machines need increased performance, expanded capabilities and added functionality. Typically, all the benefits of a new machine can be achieved through a strategic upgrade of the tension control components of your machine.
Solve & Prevent Tension Control Problems
Registration Variation
Web Width Variations
Waste
Stretching
Web Tracking
Curling
Baggy Edges
Web Breaks

3. The Experience You Depend On
MA Press Upgrade
Overview
The Experience You Depend On
Montalvo has designed specific total tension control upgrade packages unique to the requirements of Mark Andy Presses. With years of experience upgrading various Mark Andy Presses, Montalvo has both the technical expertise and the knowledge to create a cost effective, reliable, performance driven, and quick return on investment upgrade for your MA Press.
It’s All About Results
Increase machine flexibility to run multiple types of materials & lighter substrates
Run from full roll to core
Decrease waste
Improve end product quality
Increase line speed
Increase profitability
Easier operator set-up and operation
Decrease maintenance downtime
Extends machine service life
Fast and easy installation

4. Step 1: Replace Tension Brake
MA Press Upgrade
Step 1: Replace Tension Brake
*Existing magnetic particle brakes create excess tension. Even at zero volts applied, there is still substantial friction on the unwind.
*Existing pulleys and belts create additional friction on the unwind shaft
*This residual friction creates increased torque limiting the materials that can be run on the machine, and limiting the ability to run all the way down to the core.
MA4120 & MA2200 Press with existing mag particle brake, pulleys ,and belt

5. MA Press Upgrade
Step 1: Replace Tension Brake
Replace existing mag particle brake with Montalvo CD or CS Series Brake
Easy Installation
Remove existing brake, belt, shaft wheel, and hub
Drill and tap module standoffs (using a supplied template)
Mount new CD/CS brake using existing shaft and friction modules
Install I/P Converter, plumb brake and connect air supply
*(if MA hold back brake will also need to be disengaged)

6. Precise Tension Control to Run From Full Roll to Core
MA Press Upgrade
Step 1: Replace Tension Brake
Results
Precise Tension Control to Run From Full Roll to Core
Wider Torque Range Allowing You to Run Multiple Materials
Greater Heat Dissipation
Increased Line Speed
Decreased Maintenance Time

7. Replace Existing Dancer Assembly with Montalvo Load Cell Roller
MA Press Upgrade
Step 2: Install Load Cells
Replace Existing Dancer Assembly with Montalvo Load Cell Roller
*Existing dancer does not provide actual web tension feedback from your material.
*Newly installed CD/CS Brake eliminates tension upsets the dancer is meant to correct.
Easy Installation
Remove existing idler roll
Drop in Load Cell Roll replacement
Web material to bypass dancer and utilize the load cell roll

8. Increased End Product Quality
MA Press Upgrade
Step 2: Install Load Cells
Results
Increased End Product Quality
Continuous load cell measurements keeps your material at the precise tension level required throughout your process, maximizing end product quality from full roll to core.
Decreased Waste
Load cells sensitive to the slightest changes in tension allow your controller to take even minimal corrective action so you are producing profit and not scrap.
Increased Productivity
Instantaneous, reliable, and repeatable tension measurement gives you the productivity and profitability increases you require.

9. Install New Montalvo Tension Controller
MA Press Upgrade
Step 3: Install Tension Controller
Install New Montalvo Tension Controller
Bringing it all together to create a high performance, high quality, automated closed loop tension control system
With the new load cell roller and braking system installed, the controller utilizes feedback from the load cell to determine the tension of the web and then controls output to the brake to precisely maintain the desired tension.
This creates and automated and continuous system of process feedback and control, expanding and maximizing the capabilities of your machine.
Easy Installation
Mount tension controller
Connect load cells, I/P converter and power to the controller
Connect PDA valve and/or M4 analog meter (if applicable)

10. MA Press Upgrade
Complete

11. Tension Control Upgrade
Montalvo Mark Andy
Tension Control Upgrade
Increase machine flexibility to run multiple types of materials & lighter substrates
Run from full roll to core
Decrease waste
Improve end product quality
Increase line speed
Decrease set-up time
Increase profitability
Easier operator set-up and operation
Decrease maintenance downtime
Extends machine service life
Fast and easy installation
Contact Your Local Montalvo Applications Specialists Today for a Free Consultation for Upgrading Your Mark Andy Press