International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

In roll-to-roll systems like wet wipe production, the synchronous and smooth unwinding of the web material with constant tension is critical for product quality and production efficiency. Traditional constant belt braking mechanisms cause tension issues due to varying bobbin diameter and friction-induced heating, leading to web undulations, stretching, and breaks in sensitive materials such as wetlace. To overcome these operational challenges, an automatically controlled braking and accumulator system has been developed. The system instantly measures product tension by monitoring web position using a laser ruler and dynamically adjusts the pneumatic brake force via a high-frequency PID algorithm updated every 5 milliseconds. Furthermore, a constant pressure pneumatic piston acts as an accumulator, balancing the web’s vertical movements and dampening instantaneous tension variations. This system, compliant with Industry 4.0 principles and based on real-time feedback, solves critical tension control problems, ensures continuity in product quality, and establishes a new concept that is a pioneering example in the global market.

Nonwoven winding machines are critical equipment where the structural integrity of the main drum directly impacts the quality and stability of the final product. This study presents the mechanical analysis and braking system design for a main winding drum (Diameter 400 mm) in a high-speed nonwoven application, driven by Finite Element Analysis (FEA) for stress minimization. The load analysis, based on the Principles of Static Equilibrium, determined the total maximum load on the drum supports, considering a maximum spool weight of 1500 kg and a nip force of 1962 N. The resultant total load applied on the supports was calculated as approximately 11.5 kN. The FEA, utilizing ST37 steel, revealed a maximum Von Mises Stress of 1.754 MPa and an extremely low maximum deflection of 0.005 mm. This confirms an optimal factor of safety (FS approx 134) and high rigidity. Furthermore, the paper addresses the safety requirement for emergency stopping from a maximum speed (omega = 50 rad/s). The minimum required braking torque was calculated as 235 Nm, while the selected COREMO PNEUMATIC CALIPER BRAKE B-2N system provides 306.8 Nm, ensuring reliable and controlled deceleration. The results validate the structural and functional design, contributing to enhanced machine performance and operational safety.

This study details the thermal and fluid dynamic performance analysis and geometric optimization of a compact plate heat exchanger designed for waste heat recovery in industrial drying systems. The objective is to preheat fresh process air (25oC) to a target temperature range of 65–70 oC by recovering heat from high-temperature exhaust air (84 oC inlet, 36,000m3/h flow rate). The methodology integrates fundamental thermodynamic assessment (LMTD and  methods) with Computational Fluid Dynamics (CFD) for detailed flow and temperature mapping. Critically, a Differential Evolution (DE) algorithm was applied to optimize plate geometry, channel size, and profile arrangement, subject to a mass constraint, to maximize heat transfer. Results confirm that the optimized design achieves 18-25% natural gas savings and 27.5% higher efficiency compared to conventional systems. This hybrid approach validates the optimized heat exchanger as a highly sustainable and economically viable solution for industrial thermal management.

This study presents the comprehensive design and architectural modeling of a robotic-based multi-packaging machine developed for high-speed and high-precision packaging processes. The system integrates a Delta robot-based pick-and-place unit, advanced servocontrolled horizontal packaging modules, and a modular conveyor design engineered for multi-product stream transfer. This work investigates the core operational challenges, including product flow management, optimized grouping strategies, dynamic conveyor synchronization, coordination of multi-axis servo movements, and the system’s overall operational efficiency. The results indicate that the developed system operates with high stability, achieves superior precision, and significantly enhances production throughput by providing automatic parameter optimization based on product variety, thereby aligning with modern Industry 4.0 requirements.

In this study, cutter blades were designed to shred nonwoven waste fabrics by being positioned on an existing shaft. In this context, the design was carried out by considering the shear stress and density of the material to be shredded. During the design process, the total deformation conditions on the cutting surface were examined, and the stress concentration regions were identified using the von Mises approach to determine the necessary mechanical properties of the cutter blade. At this stage, the most suitable cutting tool material was selected. To ensure the torque from the motor is evenly distributed to the cutting edges and to meet the requirements of the material to be cut/shredded as well as the targeted machine capacity, various tool geometries were created and designed. In this context, analyses were performed to determine the effect of the selected geometries on the load distribution on the cutting edges, and the optimal tool geometry was decided.

In this study, the design and modeling of a shredding unit intended to fragment nonwoven waste fabrics and prepare them for recycling were carried out. Stress analyses were performed on the shaft attached to the blade, along with motor power and torque analyses required for smooth operation, and mass flow calculations. Mathematical models were developed based on these data. Additionally, structural analyses of the chassis, necessary for stable system operation, were conducted, resulting in a comprehensive mathematical model of the entire system.

There are many different models and types of heat exchangers depending on the area of use. The type of fluids involved in heat transfer and their temperature play a critical role in selecting the appropriate model. Common heat exchangers include plate exchangers, tube-type exchangers, air-cooled exchangers, and graphite exchangers. In this study, a sustainable and original heat exchanger system was designed to increase energy efficiency and reduce natural gas consumption by utilizing the waste heat from natural gas. The design prioritizes ease of maintenance and cleaning. Detailed engineering analyses were conducted, and critical engineering errors identified in previous heat exchanger designs were resolved. The developed designs were validated through test studies and experiments, leading to the final design after an optimization process.
As a result of the study, a high-capacity, energy-efficient, and sustainable heat exchanger integrated with modern technology was developed.

In this study, an original design was developed to address the issue of insufficient packaging speed, a key challenge in wet wipe production lines. A separator/distributor was developed that enables a single wet wipe machine to work with three packaging units during the transfer of products from the wet wipe preparation unit to the packaging process. The developed separator moves angularly on the vertical axis and can transfer products to conveyor groups leading to three different packaging lines. Additionally, a unique movable upper conveyor was designed to operate across a range of product heights, which applies pressure to the products during movement to prevent them from scattering. One of the primary design criteria for the conveyor is lightweight construction, and this was a key focus during development. To achieve angular motion, a servo-driven flywheel mechanism was designed. The machine is equipped with sensors for Industry 4.0 compatibility, ensuring communication between units. In case one of the packaging machines becomes inactive, the separator automatically redirects the product feeding process to the remaining packaging machines, ensuring uninterrupted production.

In wet wipe machines, equipment such as tanks, pumps, pipes, and valves that come into contact with the wet wipe solution, conveyor belts, and steel surfaces with which the liquid comes into contact, must be disinfected at regular intervals under hygienic production rules. Disinfection is carried out using hot water, alcohol-based disinfectants, surfactants, detergents, oxidizing agents, or a mixture of all these methods. In current applications, liquids are drained manually from preparation units or tanks, and machine surfaces are cleaned manually. Cleaning and sanitation is done by hand. At the same time, performing some cleaning scenarios is harmful to human health because of hot steam or water, chemical cleaning steam, etc. So, it is impossible to ensure the hygiene level of systems. In this study, safe by design and prevention approaches were used and a system equipped with several measurement sensors was designed to work with different sanitary liquids and their preparation units according to sanitary recipes, producing a report at the end of the cleaning process. There are devices such as pH meters, temperature sensors, pressure sensors, and several water analyzers in the system, and it is decided that cleaning is completed by processing the data from these sensors. This article describes the system developed in compliance with industry 4.0 applications

One of the most critical consumable expenses in the production of wet wipes is the anvil and knife set used in the cutting unit. Blades that lose their cutting ability over time and become unable to perform their task pose a significant challenge. As wet wipes are essential products for maintaining hygiene and directly affect human health, even the slightest disruptions in production conditions are unacceptable. To ensure the quality and consistency of wet wipe production, it is vital to analyze the factors affecting the strenght of cutting blades and implement the necessary precautions. One of the key factors influencing the wear of cutting tools is the mechanical strength of the tool’s carrying unit. This paper explores the importance of cutting tools in wet wipe production, the role of mechanical strength in maintaining their effectiveness and application of mathematical modeling to design.

Wet wipe machines are machines for high capacity production at high speeds. Even the short downtimes of the machines in the production area lead to huge losses for manufacturers. However, in these machines; unexpected breakdowns such as belt breakage, bearing damage, sensor motor failures, pneumatic air leaks are frequently encountered. In order to prevent unwanted stoppages, a sensor, actuator and plc based application has been implemented to prevent failure parameters and to detect faultlessly by monitoring the operation parameters. As a result of the studies carried out, our wet wipe machines that we produce have been adapted to the industry 4.0 concept.

Packaging machines using for wet wipes operate at high speeds and the demand for speed in the relevant market is constantly increasing. The most important difficulty to faster operation of these machines is the relative slowness of the units used for sealing the packages. In this study, it is aimed to design a unique mechanism that can work at 160 packages per min instead of sealing unit which is still operating at 120 packages per min, and to verify the design by mechanical analysis. For this purpose; instead of the existing sealing unit driven by a single servo motor, the horizontal and vertical movements are separated and driven by two servo motors to achieve %33 more speed.