Reel Turn-Up System
Our heritage company, Sandar, pioneered the original turn-up device, introducing safety, reliability and efficiency to reel change in the paper, nonwoven and converting industries. Since the introduction of the TUSA reel turn-up system we have continued to improve the performance of our devices whether the process is moving at 1,000 fpm or 4,000 fpm. Our patented backup solution adds immediate recovery during upset conditions.
Pioneering Automated Reel Turn-Up Since 1988
Sandar Industries built the first automated turn-up device for paper machines, and that engineering line runs unbroken into the TUSA systems Monarch Paper Group builds today. Every system in the range shares the same design principles: complete modular construction, no special tools for maintenance, and modules that can be disassembled and replaced in under five minutes. Quick-disconnect pneumatic hoses mean a module swap does not become a shift-long job.
How Our Automatic Reel Change System Works
A reel turn-up transfers the running web from a full parent reel to a new empty spool without stopping the machine. The TUSA system loads paperband onto the track, applies pressure-sensitive adhesive tape, delivers the band to the nip, and cuts and feeds it so the web transfers cleanly to the new core. Loop-based models use a loop box and an analog signal for automatic loop adjustment; the TUSA 5 replaces the loop entirely with UNI-CHARGER loopless technology.
TUSA 1 — The Simplest Automated Turn-Up
TUSA 1 is the purest and simplest automated turn-up system on the market today, built for ease of operation and the lowest maintenance cost. Adhesive application is manual. Loading is manual-assisted with an automatic stop at the end of the track, and the counter is set to the track length so paperband stops automatically and initiates the loop sequence.
TUSA 3 — The Universal System
TUSA 3 is the most universal system in the range, offering reliability and ease of maintenance across most applications. Maximum load speed is 150 fpm (46 mpm), adhesive applies in seconds using manufacturer-supplied consumables, and brake activation is measured in milliseconds. Load, loop, cut and feed are all automated, and the standard reel speed selector offers up to five predetermined loop lengths.
TUSA 5 — Fully Automated, Loopless
TUSA 5 is the first integrated, intelligent, fully automated turn-up system designed for high-speed and dynamic reel applications. UNI-CHARGER loopless technology overcomes the speed limitations of traditional loop designs: unidirectional unwind delivers paperband smoothly, de-curling, realigning and protecting the band for higher yields and reliable feeds. Adhesive length is programmable with optical adhesive detection and a self-locking detection plate. The Nip Acquisition Detection Algorithm (NADA) provides precision timing as reel conditions change, and dynamic reel speed selection eliminates missed turn-ups at high speed.
Over Under EasyFlo — Dual Band with Independent Back-Up
Over Under EasyFlo is the first dual band delivery system with an independent back-up, combining EasyFlo with loopless technology in a single profile. The back-up band shares the optimised injection point and track position, and can be initiated manually or automatically with independent load, feed and break. It is adaptive to any TUSA system.
Reduce Broke & Downtime with Seamless Web Transfer
A missed turn-up costs a reel. Every failed transfer means broke to repulp, an unplanned slowdown and, on a fast machine, a wrap. The whole point of an automated turn-up is that the transfer happens the same way every time, at machine speed, without an operator at the reel. That is what the patented backup recovery system protects: if the primary band fails, recovery is immediate rather than a stop.
Spare Parts, Maintenance & 360 Service
Monarch Paper Group maintains paper machines, including equipment built by other manufacturers. Our 360 service covers training, spare parts and scheduled maintenance for TUSA systems and for OEM turn-up equipment already installed in your mill.
Frequently Asked Questions
What is a reel turn-up system and how does it work?
A reel turn-up system transfers a continuous paper web from a full parent reel to a new empty core without stopping the machine. Monarch’s TUSA range does this at machine speeds from 1,000 to 4,000 fpm, using paperband and pressure-sensitive adhesive tape to carry the web across to the new spool.
How does TUSA compare to IBS reel change systems?
Both are automated reel change solutions for paper mills. TUSA offers a patented backup recovery system, a completely modular design with five-minute module replacement, and the engineering lineage of the company that pioneered the original turn-up device.
Does TUSA work for nonwoven converting lines?
Yes. TUSA reel turn-up systems are engineered for paper machines, nonwoven lines and converting operations.
Can Monarch supply paperband and tape for a non-TUSA machine?
Yes. Monarch’s paperband and PSAT products are engineered to perform in both TUSA systems and OEM reel turn-up machines from other manufacturers.
Talk to Monarch Paper Group
Request information about our reel turn-up systems. Contact Monarch Paper Group or call 770-423-0934.
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