Genesis was hired to create a controls system for a web line being built by a third party. Partway through the process, the third party was dismissed from the project and Genesis' involvement was expanded to redesign the complete production line. Genesis re-engineered and created a line that met specification and worked for all project goals, using much of the equipment that had already been purchased.

However, the line was never put into full production, as the client changed their process specification dramatically after completion of the line. To meet the new project goals, Genesis was again brought in to redesign the production line. We were able to repurpose much of the existing equipment to make the line compatible with the new different product handling paradigm. The line is currently being used for prototype production.

Details are proprietary, but this line, in both of its forms, is a large web handling application, ranging up to 2 meters in width. In its first incarnation, this machine had over 40 servo axis all working in concert to provide a continuous motion roll-to-sheet process with coating deposition, precision cutting and layered placement, as well as seal welding and final crosscutting.

In the second iteration, the web is still handled in continuous motion, but the line has been converted to a vertically oriented dual layer machine, with coating material deposited directly between the two layers of substrate, which are then laminated together, seal welded and cut to size.

Genesis continues to be involved with additional supporting equipment design and manufacture, as well as further modification to suit changing project goals.