Unlock Faster Splicing and Reduce Energy Costs: The Smart Motor-Brake System Revolutionizing Corrugated Production

Minimize paper breaks, boost productivity, and recover energy with a single upgrade

In the corrugated board manufacturing industry, the production process faces several technical challenges that can significantly affect both product quality and overall efficiency. Among the most pressing issues are the need to slow down the line during splicing, frequent paper breaks, and rising energy costs, all of which have a direct impact on productivity and profitability.

REVOLUTION: THE MOTOR BRAKE

To address these challenges, Renova has developed and patented an innovative solution: Revolution, a 100% Plug&Play motor brake. This advanced system combines a multi-disc pneumatic brake with a regenerative motor, working together to ensure optimal web tension throughout the entire production line.

The pneumatic brake assists the motor during daily operations and engages in emergency stops, significantly reducing brake pad wear. The motor plays the primary role by carrying out the web tension control while providing great sensitivity as it does not suffer performance drop due to the heat.

PROCESS IMPROVEMENTS

Splicing is a critical phase in corrugated board production, as it ensures uninterrupted operation of the line. To reduce the risk of paper breaks, one of the leading causes of downtime and productivity loss, the line speed is often significantly reduced during this process. However, a decrease in splice speed can negatively impact overall production efficiency. It may lead to diminished board quality, a higher occurrence of defects, and reduced throughput. Industry data shows that a 10% reduction in splice speed can result in up to a 15% decrease in weekly production output.

Revolution solves this issue by accelerating the reel directly on its axis, thus overcoming the initial inertia instead of pulling the paper web. This allows for a splicing speed increase of at least 25%, while also minimizing paper breaks and unscheduled downtimes. Additionally, the system enables consistent starch and temperature settings throughout the process, which helps maintain the highest product quality.

REGENERATIVE BRAKING 

In 2025, managing energy costs has become a strategic priority in response to market volatility. Energy accounts for approximately 20% of operational expenses in the corrugated cardboard sector. According to industry research, companies adopting energy-efficient solutions can reduce their operating costs by up to 10%, delivering tangible benefits in terms of competitiveness and sustainability.

Traditional pneumatic brakes waste the energy generated during braking by releasing it as heat. Revolution introduces a breakthrough: it recovers part of that wasted energy, converting it into usable electricity. Specifically, the system can generate up to 10 kWh of recovered energy per corrugator line (2 kWh per roll stand), which is instantly fed back into the plant’s electrical line, resulting in an estimated 7% reduction in energy costs.

REVOLUTION 4.0 INTEGRATED SYSTEM

As a fully integrated Industry 4.0 system, Revolution includes:

• The compact design of the energy-recovery hybrid brake makes it suitable for retrofitting all existing roll stands.

• A user-friendly control panel that communicates directly with the ERP system, enabling motorized rewind of the roll and eliminating manual intervention, improving both productivity and operator safety.

• A centralized cabinet housing all electronics needed to manage a splicer and up to four Revolution units, streamlining and optimizing the entire process.

TECHNICAL INNOVATIONS

Building on its advanced features, Revolution has taken a significant leap forward with the introduction of its technical updates:

• Semi-Automatic Selection of Roll Acceleration Force
  Equipped with a roll diameter and speed sensor, and optionally, a detection sensor, the system calculates and suggests the optimal acceleration force directly on the Revolution control panel. This ensures precise setup and improved splicing efficiency.

• Push-Button Panel for Motorized Rewind
  A new dedicated push-button panel enables motorized rewinding of the roll in both clockwise and counterclockwise directions. Positioned near the splicer, it significantly speeds up operations and enhances operator convenience.

Revolution introduces a smarter approach to managing critical phases of production, with benefits that extend across performance, energy use, and process continuity. Developed and patented exclusively by Renova, Revolution demonstrates how targeted innovation can lead to meaningful improvements in productivity, product quality, and sustainability across the production line.