Servo-controlled knife pleating systems and cutting systems for filter and pleated product manufacturing from Berlin.
FALTEC Falt- und Sondermaschinen GmbH & Co. KG
13053 BerlinNew on Amplifa
Special machinery for the pleating process since 1995
FALTEC Falt- und Sondermaschinen GmbH & Co. KG develops and manufactures in Berlin servo-controlled knife pleating systems and cutting systems for the production of filter packs and pleated products. The product range includes Standard knife pleating systems in the S, V, X and P versions with pleating speeds of up to 250 folds/min, special systems with pleating heights of 1.5 to 160 mm and working widths of up to 3000 mm, as well as filter pack cutting systems. A modular system with more than 40 variants – from the unwinding system to the machine infeed and cross cutter – allows the extension and modernization of existing systems. Filter and sun protection media such as PP, PA, PU, nonwovens, activated carbon, heavy wire mesh and sintered metal nonwoven mats up to ten layers are processed. Characteristic features include the patented parallelogram technology, the patented infrared heating technology with up to three heating zones, Softtouch and Presstouch pleating, and Siemens control and drive technology. Customers include renowned filter and pleated product manufacturers worldwide; in addition, FALTEC offers process engineering consulting, teleservice and process data visualization.
- Site
- Berlin
- Processes
- Knife pleating (Standard knife pleating systems), Knife pleating (Special knife pleating systems, pleating heights 1.5–60 mm or 50–160 mm), Longitudinal cutting (longitudinal cutting system EL-LSQ / LSA, perforation and edge trimming), Cross cutting (cross cutting system QS), Filter pack cutting (filter pack cutting system PS), Saw gate cutting (saw gate LSSG), Special pleating, Modernization / conversion and extension of existing pleating systems (modular system, more than 40
- Materials
- Polypropylene (PP), Polyamide (PA), Polyurethane (PU), Nonwoven, Activated carbon, Wire mesh, Sintered metal nonwoven mats, Filter media (filter and sun protection media)
- Certificates
- Process data processing and visualization, Teleservice via LAN, Pleat height measurement directly in the infeed guides
- Founded
- 1995
- Industries
- Filter manufacturers, Pleated product manufacturers (sun protection)
- 01
Process engineering consulting and design
- 02
Manufacturing of the system modules
- 03
Commissioning and programming (TIA Portal, SIMOTION)
- 04
Modernization/retrofitting of existing systems
- 05
Teleservice and process data visualization
- 06
Supply of pleating materials
Materials and processes
Polypropylene (PP)
Woven pleating material for filter and pleated product production in the pleating systems.
Polyamide (PA)
Synthetic fabric for processing up to ten layers.
Polyurethane (PU)
Pleating material for filter and sun protection media.
Nonwoven
Pleating medium for filter packs, also processable in multiple layers.
Activated carbon
Pleating material for filter media with adsorption function.
Wire mesh
Heavy wire mesh up to 12 kN horizontal counter-pressure, among others in the X version.
Sintered metal nonwoven mats
High-temperature and filtration material for special pleating applications.
Infrared heating technology (patented)
Three heating zones heat the pleating head up to 200 °C instead of the pleating pack, with short heating and cooling times.
Parallelogram technology (patented)
Encapsulated, lifetime-lubricated bearings prevent contamination of the pleating media.
Siemens SIMOTION control system
System and drive control with programming in TIA Portal and process data processing.
Locations
Berlin
DEManufacturing and administration
- Materials
- PP, PA, PU, nonwoven, activated carbon, wire mesh, sintered metal nonwoven mats
- Standard knife pleating systems (S, V, X and P versions)
- Special knife pleating systems
- Filter pack cutting system (PS)
- Modular system with more than 40 variants (AR, EL, LSQ/LSA, VG, HG, LSSG, QS)
- Siemens SIMOTION control, TP2200 COMFORT touch panel
- Alpha Wittenstein TPM/TPMA High Torque servo drives
Systems and machines
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Knife pleating (Standard knife pleating systems)Forming | – | 2400 mm | – | – | PP, PA, PU, nonwoven, activated carbon, wire mesh, sintered metal nonwoven mats |
| Knife pleating (Special knife pleating systems, pleating heights 1.5–60 mm or 50–160 mm)Forming | – | 3000 mm | – | – | PP, PA, PU, nonwoven, activated carbon, wire mesh, sintered metal nonwoven mats |
| Longitudinal cutting (longitudinal cutting system EL-LSQ / LSA, perforation and edge trimming)Machining | – | – | – | – | filter media, wire mesh |
| Cross cutting (cross cutting system QS)Machining | – | – | – | – | filter media |
| Filter pack cutting (filter pack cutting system PS)Machining | – | – | – | – | filter media, nonwoven |
| Saw gate cutting (saw gate LSSG)Machining | – | – | – | – | filter packs |
| Special pleatingForming | – | – | – | – | filter and sun protection media |
| Modernization / conversion and extension of existing pleating systems (modular system, more than 40Engineering | – | – | – | – | – |
| Technical consulting and investigation of complicated pleating operations (process engineering)Engineering | – | – | – | – | – |
| Thermal pleating with patented infrared heating technology (up to 200°C, 3 heating zones)Heat treatment | – | – | – | – | filter media, nonwoven, wire mesh |
16 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Standard knife pleating system (S version: up to 150 folds/min, 4 servo drives) | FALTEC S version | – | Working widths 600–2400 mm, pleating heights up to 50 mm | – | Berlin |
| Standard knife pleating system (V version: up to 200 folds/min, 4 servo drives) | FALTEC V version | – | Mass filter production up to max. 3 layers, single layer up to 250 folds/min | – | Berlin |
| Standard knife pleating system (X version: up to 50 folds/min, 5 servo drives) | FALTEC X version | – | heavy wire mesh up to 12 kN horizontal counter-pressure | – | Berlin |
| Standard knife pleating system (P version: up to 120 folds/min, 6 servo drives) | FALTEC P version | – | up to 7 layers with supporting fabrics of wire, plastic | – | Berlin |
| Special knife pleating system (servo-controlled) | FALTEC | – | Pleating heights 1.5–60 mm or 50–160 mm, working width up to 3000 mm | – | Berlin |
| Unwinding system (module AR) | FALTEC AR | – | – | – | – |
| Machine infeed module (EL-MAB material deceleration, EL-VS pre-cutter, EL-VW preheating) | FALTEC EL | – | material up to ten layers | – | – |
| Longitudinal cutting system (module EL-LSQ / LSA) | FALTEC LSA | – | – | – | – |
| Vertical counter-pressure (module VG) | FALTEC VG | – | – | – | – |
| Horizontal counter-pressure (module HG) | FALTEC HG | – | – | – | – |
| Saw gate (module LSSG) | FALTEC LSSG | – | – | – | – |
| Cross cutting system (module QS) | FALTEC QS | – | – | – | – |
| Filter pack cutting system (module PS) | FALTEC PS | – | – | – | – |
| Servo drives TPM/TPMA High Torque, actuators | Alpha Wittenstein TPM-/TPMA High Torque Servo | – | – | – | – |
| System/drive control | Siemens SIMOTION (programming in TIA Portal) | – | – | – | – |
| Visualization/operating panel, 22-inch touch | Siemens TP2200 COMFORT | – | – | – | – |
Additional services
Reference customers
Process capability and reproducibility
The systems offer high process capability, exact repeatability and true reproducibility through direct path measuring systems without reference travel. All process data such as blade type, temperatures and material structure are stored, retrieved reproducibly and optionally transferred to host computers.
| Evidence | Berlin |
|---|---|
| Process data processing and visualization | |
| Teleservice via LAN | |
| Pleat height measurement directly in the infeed guides |
Company history
- 1995
Founding of FALTEC with the vision of revolutionizing the pleating process through innovative physical and technical applications.