Updated: March 10, 2026
High-precision web processing applications like coating, slitting and rewinding require steady web tension measurement and control to ensure excellent product quality and efficient operations. Fluctuating tension creates product flaws and material loss while causing expensive operation interruptions. Swiss-based Force Measuring Systems (FMS), a leader in force sensor technology, has pioneered a solution: The FMS-segFORCE segmented tension roller. This roller offers an innovative approach to measuring tension along the web width, resulting in enhanced process control. In this post, we will examine the fundamental benefits of segFORCE and demonstrate how it serves as a useful tool to profile web tension fluctuations. Segmented rollers are often used alongside web tension measurement and control systems used in coating and extrusion lines.
What is a Segmented Tension Roller and Who Needs It?
In a simple overview, a segmented tension roller consists of a main spindle shaft that supports a certain number of force (tension) sensors. The number of force sensors is dependent upon the web width and application. Each force sensor transmits a signal to the amplifier, which is housed on the side of the unit. A power port along with two Ethernet ports for data transfer is also embedded into the side of the unit for easy connectivity.
Key Web Processing Applications That Benefit from Segmented Tension Rollers:
- Battery & Fuel Cell Production (Anode Coating)
- Battery & Fuel Cell Production (Cathode Coating)
- Battery & Fuel Cell Production (Calendering)
- Foil Production
- Adhesive Coating
- Blown Film Extrusion
- Lamination
- Roll Inspection
- Web Slitting and Rewinding
- Other Web Coating & Converting Applications
See our film & sheet extrusion measurement solutions and coating measurement solutions to learn how these processes are monitored and controlled in production.
The segmented tension roller is installed beneath the web path to measure material tension, which is especially valuable in film and sheet extrusion processes where tension stability directly affects thickness measurement and product quality.
Advantages of Segmented Tension Rollers for Precision Web Tension Monitoring
1. Superior Tension Monitoring
- Provides up to 50 measuring points along a single roller,enabling detailed web tension profiling across the entire material width.
- Enables detection of even the smallest tension deviations between segments which a conventional force sensor cannot.
2. Enhanced Process Control & Quality
- Allows for real-time monitoring, ensuring quick identification of faulty winding shafts or differential shafts in slitting and rewinding applications.
- Delivers a detailed tension profile, helping detect and eliminate process or material-related faults efficiently.
- Facilitates fast quality assessment of parent rolls, ensuring consistent production and minimizing waste.
3. Flexible & Customizable Design
- Configurable segment quantity, width, and position to meet specific machine requirements.
- Compatible with various roll surface options and different nominal forces to accommodate diverse applications.
- Easily integrates into existing systems due to its simple retrofit installation.
4. Seamless Integration & Data Processing
- Features a PROFINET interface for direct PLC integration and real-time data visualization.
- Provides clear visualization of individual web sections, allowing operators to easily interpret data and make informed adjustments.
- Supports media redundancy and real-time data transfer, enhancing system reliability.
5. Easy Installation & Maintenance
- Can be installed universally using standard pillow block brackets for quick setup.
- Efficient design eliminates complex cabling, reducing installation and maintenance efforts.
- Pneumatic segment locking ensures secure positioning and easy reconfiguration when needed.
6. Outperforms the Competition
- No need for a middle support, multiple amplifiers, and extensive cabling as with competing rollers.
- Ultra narrow roll gap of 0.2mm compared to a 6.5mm roll gap of competing rollers, eliminates the risk of creases left in the web.
- Designed with 36mm sensor segment width and customizable to accommodate wider segments if required.
- Supplied with complementary FMS Analysis Tool software package.
Minimize Web Tension Fluctuations: Take Action Today
The segFORCE system revolutionizes web tension monitoring with its multi-point precision, real-time data insights, and seamless integration. If you want to optimize your slitting, rewinding, or coating process, this advanced solution helps you achieve greater efficiency, reduce waste, and improve product quality.
Gauge Advisor supports manufacturers across the Western United States with web tension measurement and process control solutions for coating, slitting, and extrusion lines.
We are the authorized sales partner for Force Measuring Systems (FMS) supporting manufacturers with equipment selection, process optimization, and system integration.
By: Matthew BakerFounder, Gauge Advisor LLC