The company we developed this machine for had an existing production process in place, where the most critical process step concerns folding a special medical gauze for severe burn wound treatment (3rd degree). The machinery they used was developed for this process only and unique in the world. Due to ageing and wearing effects, there was a great demand for a new machine to improve stability, quality, capability and capacity of their production. The material thickness is extremely critical for precise and reproducible folds. DEMCON was asked to replace the existing machines and automate the process even more to make this less operator dependent.
DEMCON invented a new folding principle to make these unique gauze products. This was tested first in a Proof-Of-Concept phase to check feasibility and minimize risks. Main outcome of this investigation was the required number of degrees of freedom to control the blade for folding. The complete machine, which contains two folding units, was developed and built in a second phase together with other process steps like laminating, cutting and rolling. The machine is able to create five different product variants fully automatic with high quality. The complete mechanical, electrical and software design was done by DEMCON, including HMI and data logging. The laminating and cutting part of the machine was outsourced to specialists and integrated. The machine was delivered and installed into the customer’s cleanroom on the 1st floor of their building.