Web Tension Control: Controllers, Load Cells and Amplifiers

Web tension control keeps film, paper, label stock, foil and nonwoven materials running at stable tension from unwind to rewind on roll-to-roll machines.

KENDORIC supplies automatic tension controllers, load cells, signal amplifiers and related closed-loop tension control solutions for converting lines that need stable material transport, consistent winding quality and reduced tension-related defects.

Request Selection Support

New to tension control? Read how a closed-loop system works →

System Overview

Select the sensor mounting, controller and signal path for the machine. The sensors listed below connect directly to TC100; SAMP03 provides standard outputs when the feedback is needed by a PLC, computer or another controller.

Main Components

Tension sensor and TC100, or sensor and SAMP03 for PLC feedback; brake / clutch / drive existing or supplied separately

Control Sections

Unwind, infeed, process, outfeed and rewind

Typical Materials

Film, foil, paper, label stock, nonwoven and composite webs

Selection Data

Web width, tension range, roll diameter, line speed, roller structure and brake or clutch type

Web Tension Control Products

Select controllers, signal amplifiers and tension sensors according to machine section, tension range, roller structure and required output signal.

Tension Controllers

Tension Controller

TC100 Automatic Tension Controller

Automatic tension controller for constant tension, taper tension and speed-synchronous control in unwind, process and rewind sections.

View Model

Signal Amplifiers

Signal Amplifier

SAMP03 Signal Amplifier

Signal amplifier for tension sensors, converting sensor feedback into standard output signals for PLCs, computers or tension controllers.

View Model

Tension Sensors

Pedestal-Mount Tension Sensor

LC100A Pedestal-Mount Tension Sensor

Compact pedestal-mount tension sensor with low temperature drift, stable output and good linearity.

View Model

Through-Shaft Tension Sensor

LS100A Through-Shaft Tension Sensor

Stainless-steel through-shaft tension sensor with IP66 protection for harsh converting environments.

View Model

Through-Shaft Tension Sensor

LF100A Through-Shaft Tension Sensor

Live-shaft flange tension sensor with built-in self-aligning bearings for reliable web tension measurement.

View Model

Through-Shaft Tension Sensor

LFP100A Through-Shaft Tension Sensor

Compact flange tension sensor with self-aligning bearings for easy roller installation and maintenance.

View Model

Cantilever Tension Sensor

LX100A Cantilever Tension Sensor

Cantilever tension sensor for stable tension detection with reduced sensitivity to web position changes on the roller.

View Model

Tension Control Positions

Unwind Tension Control

Maintains stable tension as roll diameter changes during unwinding.

Process Tension Control

Keeps web tension stable through printing, coating, laminating or converting sections.

Rewind Tension Control

Supports consistent roll quality during rewinding and finished roll formation.

Which tension sensor fits your roller?

Compare the mounting, load and signal details listed on each model page. A dash means that the model page does not specify that item.

Model	Mounting	Rated load	Shaft / bearing	Output	Protection
LC100A	Pedestal mount; leaf spring	5 / 10 / 15 / 30 / 50 / 100 kg	204# bearing	10 mV or 200 mV	—
LS100A	Through-shaft; stainless steel	15–100 kg	17 mm / 25 mm shaft	0–5 V / 0–10 V / 4–20 mA options	IP66
LF100A	Live-shaft flange; self-aligning	5–100 kg per sensor	1203 bearing; 40 × 17 mm	0–5 V / 0–10 V / 4–20 mA options	IP66
LFP100A	Compact flange; self-aligning	5 / 10 / 25 / 50 / 100 kg	15 / 17 / 20 / 25 mm bore	Full-bridge strain gauge	—
LX100A	Cantilever roller	10 / 25 / 50 / 100 kg	—	2 mV/V	IP54

How the sensors connect

All tension sensors listed here can connect directly to TC100 without SAMP03. Use SAMP03 to convert the sensor signal to 0–10 V, 0–20 mA or RS-485 Modbus for a PLC, computer or another controller, such as a machine that uses a PLC to control tension instead of TC100.

Direct TC100 control

Sensor → TC100 → brake / clutch / drive

Brake / clutch / drive: existing or supplied separately.

PLC signal path

Sensor → SAMP03 → PLC

SAMP03 converts sensor feedback to the standard output required by the PLC.

Typical Selection Factors

Machine Section	Unwind, infeed, process, outfeed and rewind
Material	Film, foil, paper, label stock, nonwoven and composite webs
Control Style	Manual, semi-automatic or closed-loop automatic tension control
Required Data	Web width, tension range, roll diameter, line speed, roller structure and brake or clutch type

What is web tension control?

Web tension control keeps a moving web at a suitable pulling force through the line. For the fundamentals, read what web tension is.

Open-loop vs closed-loop tension control

Open-loop control estimates tension without direct force feedback; closed-loop control uses a measured tension signal. Read how manual, open-loop and closed-loop tension control work.

Unwind, rewind, infeed and outfeed tension control

Unwind, infeed, outfeed and rewind positions have different control requirements. See where tension is controlled on a roll-to-roll line.

Main components: tension controller, load cell, brake, clutch and motor control

The sensors on this page connect directly to TC100; SAMP03 is an alternative signal path for PLCs, computers or other controllers. Brakes, clutches and motor drives are existing or supplied separately; see which tension control components KENDORIC supplies.

Common problems: wrinkles, web break, unstable winding and registration error

Wrinkles, web breaks, winding defects and registration errors need a review of the web path and running conditions. Read common tension problems and what they usually mean.

How to choose a tension controller

Start with the machine section, sensor signal and existing brake, clutch or drive interface. Use the tension control specification checklist to prepare the selection data.

RFQ checklist

Send your machine type, web width, material and installation position. We will suggest a suitable configuration.

Machine and material

Machine type, web width, material type, and material thickness or GSM.

Running condition

Line speed, installation position, power supply, and available mounting space.

Roll and tension data

Roll diameter range and maximum roll weight, core size, target tension range, and whether unwind, intermediate or rewind tension is being controlled.

Project reference

Photos, drawings, web path sketches, or current machine problem details if available.

Need a tension control configuration?

Send your material type, web width, roll diameter, target tension range, line speed and machine section for selection support.

Request Selection Support

Have a specific machine or a part to replace?

Send the machine model or a nameplate photo — we reply within one working day.

Replacing another manufacturer’s load cell? A replacement is possible when the rated load, shaft diameter and mounting dimensions match. Send the old sensor’s label and mounting dimensions so we can check the fit.

LC100A replacement checks LS100A replacement checks LF100A replacement checks LFP100A replacement checks LX100A replacement checks SAMP03 replacement checks TC100 replacement checks

Send a photo on WhatsApp Contact