Maflex America, Inc

1. How are modular converting lines redefining production efficiency and adaptability in today’s manufacturing landscape?

In today’s market, the need for flexibility and adaptability are at an all-time high.  Customers have more choices and converters sometimes need to pivot quickly to meet demands.  Our modular equipment allows the converter to handle these changes: a simple upgrade to increase speed or an additional asset that will allow for a secondary product offering.  Upgrades to existing machinery can be done to an existing line in a matter of days.

2. What core design principles differentiate modular converting systems from conventional, fixed-line setups?

Maflex’s core design has independent enclosures for each section of the machine.  This means each unit receives a power, air, and Ethernet drop.  For example, the embosser unit is completely separate from the rewinder head; they do not need to be linked by any main cables or communications.  This allows for extremely quick installations and easy upgrades in the future.

3. How do modular architectures enable faster changeovers and support high-mix, low-volume production requirements?

Maflex’s changeovers are quick to begin with – 5 minutes or less.  Our modular capabilities can allow a converter to change from a retail product to Away-from-Home in less than 5 minutes as well.  This flexibility can efficiently support several low volume runs during a single shift.

4. What are the key technological enablers driving the evolution of flexible converting solutions?

A few technologies are really accelerating flexibility: servo-driven motion control for repeatable, tool-free adjustments; recipe-based automation through modern HMIs; and standardized electrical/communication architecture (Ethernet-based networks).  Better sensing and diagnostics—like real-time tension/load feedback and condition monitoring—also reduce trial-and-error during operation and help operators maintain quality at higher speeds.

5. How can modular lines be configured or scaled to accommodate evolving production demands without major capital reinvestment?

Modular lines can be configured specifically to the converter’s need.  With each unit being independent, it is simply plug-and-play.  This makes it very easy to upgrade any part of the line without significant downtime. 

6. What role does automation and smart control systems play in enhancing the performance of modular converting lines?

Automation and smart control systems are at the heart of our converting lines.  Changeovers are tool-free and can be done very quickly with push button controls.  By using a recipe-based system, the operator simply changes the recipe via HMI, and the equipment does the rest of the work.

7. How are data integration and real-time monitoring improving operational visibility and decision-making in modular setups?

Maflex utilizes a smart supervision system we call Pegaso.  The system can monitor power usage and drops, identify wear parts based on estimated life cycle, and provide guided diagnostics and troubleshooting.  This data allows for quick assessments to give the operators confidence to run the equipment efficiently, as well as schedule down time for repairs and replacements.

This system also shows efficiencies and deficiencies throughout a production cycle, which allows the user to identify where operations can improve.

8. What are the primary integration challenges when deploying modular converting lines within existing production environments?

Honestly, there are no integration challenges.  Modular equipment is easy to install and easy to integrate with existing machinery, Maflex or otherwise.  Integrating with Maflex equipment is simply plug-and-play.  If integrating with non-Maflex equipment, we use an encoder to match machine speeds.  And because each Maflex component has its own electrical cabinet, we do not interfere with any existing machinery.  This, too, is plug-and-play.

9. How do modular converting solutions contribute to reducing downtime and improving overall equipment effectiveness (OEE)?

Modularity improves OEE by reducing both planned and unplanned downtime. Because modules are independent, maintenance or upgrades can be performed on a specific unit without a full line tear-down, and troubleshooting is faster since each section is self-contained.

Combined with fast, recipe-driven changeovers, the line spends more time producing sellable product and less time waiting for adjustments or repairs.

10. In what ways are flexible converting systems supporting sustainability goals, such as waste reduction and energy efficiency?

Our quick, repeatable changeovers reduce start-up waste and off-spec rolls, and recipe-based settings help maintain consistent quality run-to-run.  On the energy side, monitoring power usage through Pegaso highlights where energy is being consumed and where inefficiencies occur, so converters can optimize operating modes and maintenance intervals.

11. How are material innovations (e.g., sustainable substrates or multi-layer structures) influencing the design of modular converting lines?

Material innovation typically drives the need for greater process control and gentler handling. As substrates change (lighter basis weights, recycled content, different emboss patterns, multi-ply/laminated structures), converters benefit from modules that can be tuned or swapped to match the material—such as dedicated embossing, laminating, or winding configurations. Modular design makes it easier to add capability (for example, an additional emboss or different rewind option) or to upgrade controls/sensing to maintain web stability and finished-roll quality without redesigning the entire line.

12. What are the limitations or trade-offs of modular converting lines compared to traditional systems?

Maflex modular lines run at the same rates as traditional systems, so there is no limitation.

13. Looking ahead, how do you see modular and flexible converting solutions evolving to meet future manufacturing challenges?

The industry is seeing a need for more flexibility to accommodate the needs of the customer; there is no “one size fits all” solution anymore.  Machinery must be flexible to react quickly to meet the demands of the market, and Maflex has been providing these solutions for decades.