How Zwartz approaches roll-to-roll laminating for technical textiles, automotive and construction
Clients often know what they need, but not which system fits best. Zwartz has the expertise to advise on that choice. In this video, Cecile demonstrates our Klieverik belt calender and explains the machine’s applications.
How does the belt calender work?
The belt calender combines two or more substrates through thermal processing. Materials are continuously fed from roll, laminated and rewound. Unlike batch systems, roll-to-roll processing eliminates start-stop moments, making it cost-effective for larger volumes.
Bonding between layers is achieved through the thermoplastic properties of the materials themselves, or by adding thermoplastic adhesives such as films, webs or powders. By combining different adhesive systems, three material layers can be laminated in a single pass. The system precisely controls temperature, pressure and dwell time throughout the process.
Our belt calender processes materials up to 250 cm wide, with a minimum width of 100 cm.
Versatile processing options
Naast standaard roll-to-roll lamineren biedt de belt calender verschillende opties die tijdens het proces kunnen worden toegepast.
Beyond standard roll-to-roll laminating, the belt calender offers various options that can be applied during the process.
Powder scatter distributes self-adhesive powder precisely across the surface. This powder is activated in a subsequent process, providing flexibility in the production chain. Suitable for applications where direct activation is not desired.
Foil laminating adds decorative or functional layers. Think of reflective foils for safety clothing, decorative finishes for interiors or barrier foils for construction materials.
Web laminating integrates additional material layers smoothly during the process. For applications that combine multiple layers in one pass.
These processing options make the belt calender versatile for diverse applications within continuous production.
Through the right choice of adhesive, products can also be made more recyclable. Mono-material construction, where adhesive and materials consist of the same base material, makes recycling more efficient. Zwartz can advise on adhesive choices that align with sustainability goals.
When the belt calender is the right choice
The belt calender suits projects with specific characteristics.
Volume justifies continuous production. Roll-to-roll processing is cost-effective for medium to large volumes. For small test series or prototypes, batch systems like the flatbed calender are more suitable, but once production scales up, continuous processing becomes more efficient.
Materials are flexible and available on rolls. Textiles, nonwovens, foils, films and foam can be fed from roll. For rigid sheets or extremely thick materials, other systems are better suited.
Long production runs with consistent quality. The system is designed for production where precise control over temperature and pressure during long runs is essential.
Applications across sectors
We deploy the belt calender for projects in automotive, construction, technical textiles, apparel and home textiles.
Recent examples: automotive interior trim and acoustic insulation, vapour barriers and underlays for construction, filters and protective layers for technical applications, blackout curtains and upholstery.
Because the belt calender combines different processing options (powder scatter, foil, web), it works for clients who need specific functionality in the laminate.
Zwartz as knowledge partner
Clients often know what their product needs to do, but not which combination of materials, adhesive, temperature and pressure will deliver that. Zwartz collaborates from the first conversation. Which materials suit the application, which adhesive bonds both layers without stiffening the end product, at which temperature do materials remain intact?
For new combinations, test samples are made first. This can be done at smaller scale via the flatbed calender, or as trial runs on the belt calender itself to verify the roll-to-roll process. Only after approval does series production start.
Zwartz has seen thousands of combinations through production by now. That knowledge helps match the right laminating method to the application.
Our three laminating technologies (belt calender, hotmelt system, flatbed calender) cover different needs. Part of our role is choosing the right method for the project.
More information about the belt calender for your application?
Questions about continuous laminating, material combinations or process feasibility? The Zwartz team is happy to discuss which system and approach works best for your application.
Frequently asked questions
What is the maximum width you can process?
Our belt calender processes materials up to 250 cm wide. The minimum width is 100 cm.
What volumes is the belt calender suitable for?
The belt calender is cost-effective for medium to large volumes where continuous production is beneficial. For small test series or prototypes, we recommend the flatbed calender first.
Which materials can be processed?
Flexible materials on rolls: textiles, nonwovens, foils, films, foam and combinations.
Which processing options are available?
Powder scatter (self-adhesive powder), foil laminating (decorative or functional layers) and web laminating (additional material layers) can be applied during the process.
Which adhesives do you work with?
Thermoplastic adhesives such as films, webs or powders. Bonding can also be achieved through the thermoplastic properties of the materials themselves. We advise which approach suits the application.
What other systems do you have?
Besides the belt calender, we have a hotmelt system for fast adhesive application with dot coating or full coverage coating, and a flatbed calender for batch processing. Each technology serves a different purpose. We help choose the right method.
Do you also do trial runs?
Yes. For new combinations, we recommend test samples at smaller scale first before scaling up to roll-to-roll production on the belt calender. This way we verify the correct process settings.
Do you also work with customer materials?
Yes, contract laminating is possible. Clients supply materials and Zwartz handles the laminating process. We advise on the best approach for the specific combination.
Where is the belt calender located?
In Oldenzaal, the Netherlands. All production happens in-house, giving direct control over quality and lead times. Our machines run on green energy from our solar roof.
How do I start a laminating project?
Contact us with details about materials, application and volume. We discuss feasibility, material options, process settings and next steps. After that we can arrange test samples or trial runs.
