Splicing-Changeover from manual to semi-automatic process

A long-standing ROPEX customer is a manufacturer of packaging machines that are used to seal medical bags. Until now, the respective roll ends have been welded manually using a manual welding device when changing rolls. Because the customer wants to validate this process, it is planning to convert the reel change process to a semi-automated process.

In addition, the customer was looking for a solution that would allow him to set the parameters manually on a temperature controller with a display and implement them in a PLC-based system if required. After successful implementation, the machines were to be exported worldwide.

Thanks to the existing partnership with ROPEX’s Italian partner,, the customer contacted them directly for information and advice on the technical possibilities.

In the run-up to the product launch, ROPEX provided extensive technical advice to ensure that the new system met all customer requirements.

During implementation, the application experts designed a RESISTRON system and developed a suitable sealing tool that was optimized for the process parameters, such as material, pressure and time, in order to produce a repeatable sealed seam.

Before and during the implementation of the system, the customer was in close contact with the technical sales engineer from Due to the close proximity in Italy, customer support was very intensive and any questions that arose could be answered by phone or WhatsApp in addition to face-to-face meetings. Thanks to ROPEX’s expertise, potential challenges were identified at an early stage and eliminated in the run-up to implementation so that the system was ready for use immediately after installation.

On the new machine, users make the settings directly on the display control of the temperature controller. The tools then automatically seal the two roll ends together so that production of the medical bags can continue without interrupting the material. Thanks to the partial automation of the process, the roll change is significantly faster and also produces a consistent seam quality.

✓ Consistent quality: fulfillment of the repeatability of the sealing process through partial automation for satisfactory sealing results

✓ Technical support: Before, during and after implementation, the application engineers are on hand to provide technical advice and support during implementation

✓ Flexible use: If the process parameters are changed, the tools and settings on the temperature controller can be easily adjusted

✓ Energy efficiency: Energy-saving technology, as it only consumes electricity during use