These differences do not always appear immediately. They become evident over time, shift after shift, when a line maintains reliability, ease of operation and consistent output even under demanding working conditions.
It is within this concrete production dimension – made of layouts, process flows and specific engineering details – that the most relevant technological choices take shape.
“The concept behind the HERMES line, in all its configurations, stems from direct observation of daily production dynamics. It is a response to real needs, measured in the field and translated into practical operational solutions,” adds Eng. Luca Mazzotti.
Project type and application context
“The line was developed for a U.S.-based converter active in tissue and nonwoven converting, with a strong presence in the professional market,” Martin Kyles, Maflex America President and CEO, continues. “The application context is characterized by high volumes, a wide range of formats and products serving the professional cleaning, hospitality, industrial and institutional supply sectors.”
In such a scenario, the ability to manage different product types – from toilet tissue to professional drying products – requires reliable, flexible equipment capable of maintaining consistent standards across multiple production shifts. The line configuration was therefore designed to address the need for operational continuity, adaptability, and process control – key factors for companies operating in structured and highly competitive markets such as North America.
Production continuity and coreless configuration
In professional production environments, operational continuity is not merely a matter of speed, but of long-term process stability. A continuous line must ensure a steady flow even when format, basis weight or finished product configurations vary.
In the HERMES coreless configuration, the value does not lie in simplifying the process itself, but in enabling this product type to be integrated within a continuous line. This reduces the need for dedicated machinery while optimizing investment, layout and workforce management. Modularity allows the system to be configured according to available space and required volumes, preserving functional coherence and ease of operation.
CES module: an industrial strategy, not just an accessory
The integration of the CES (Coreless Extraction System) extends coreless production to a standard or existing continuous line through the addition of a single module downstream of the tail sealer. This approach avoids the introduction of dedicated equipment and enables a more rational management of investments, floor space and production resources – an increasingly relevant aspect in professional tissue converting environments.
Line configuration: coherence, continuity and process control
The HERMES line developed by MAFLEX was designed as a complete system, in which each machine contributes to the overall stability of the process. The unwinding section integrates two UT200 unwinders, ensuring constant feeding and smooth web management.
The HERMES industrial rewinder, in its standard coreless configuration with dedicated mandrel insertion and extraction station, represents the core of the line, ensuring production continuity and repeatable performance. The process is completed by the METIS tail sealer, designed to handle a wide range of products, and equipped with a linear guide gluing system.
Downstream, the LA40 log accumulator, with a capacity of up to 40 logs, plays a key role in decoupling different sections of the line, absorbing brief stoppages upstream or downstream without compromising overall process continuity.
The LADON Plus log saw, with speeds of up to 120 cuts per minute and equipped with an automatic universal clamp system, contributes to maintaining a balanced and highly efficient production flow.
“The entire tailor-made configuration is the ideal response for this type of converter, oriented toward high-volume professional production and requiring reliability, operational simplicity and seamless integration between the different stages of the production process,” concludes Martin Kyles.
