Case Studies

Double E is a solutions provider. The company engineers and applies its products with over 40 years of industry experience behind it, generating thousands of success stories. Please find a few examples of how Double E has helped customers below.

Bag Manufacturer Alleviates Tension Issues with Integrated Control System

Recently one of the largest bag manufacturers in the country was struggling with web tension control in the unwind section of the converting process. The paper material was spooling and tugging at the line, making it necessary to run at slow speeds and with constant manual adjustments. A combination of Double E / Re web accessories, including an integrated tension control system solved the problem.


Double E utilized the customer's existing unwind stand by engineering a shaft, chuck and brake combination that would bolt directly to the stand. The new unwind components included a three-inch expanding strip shaft, two safety chucks and a single Re CX.200 pneumatic brake. This combination made it possible for the customer to unwind multiple roll widths while ensuring roll security and easy loading. To measure and control the tension, Double E provided Re CF.85 load cells and a Re EP.25 control system with a T-One tension controller. Now the customer has the ability to adjust the set-point and provide a smooth even tension throughout the unwind.


The upgrade also used a Re web guide shifting actuator AT guide to facilitate lateral movement of the stand. By having this flexibility, the customer eliminated a secondary problem of potential misalignment of the laminated layers.


After the installation, a Double E field engineer met with the machine operator to provide training for the T-One controller. The customer was so pleased with the process improvement results on this part of the machine that a secondary project is now underway. Double E will provide a solution with an open loop control and brake for the plastic film unwind portion of the same machine. Currently the customer is using a system of weights being hung from a pulley attached to the shaft. This primitive, completely manual system is difficult to maintain and imprecise. Double E's replacement will include an additional shaft, chuck and brake combination that will link into the existing tension controller. The entire line will be easy to control from one location.