Proof of Concept
for automated pleating systems

As part of a proof of concept, a largely automated system for processing pleated filter media was developed. The objective was to evaluate critical process steps under real operating conditions and to validate them reliably prior to investment in a full-scale production line.

The focus was on material-sensitive processing under continuous operation. This included precise cutting to a defined number of pleats and selective trimming of the top layer of the three-layer material, in preparation for the subsequent welding process. These steps are critical to product quality and cannot be fully evaluated by theoretical analysis alone.

The result of the proof of concept established the technical foundation for subsequent automation steps. It demonstrated consistent material handling and provided reliable data on cycle time, cutting precision, and process stability. Based on these findings, subsequent process steps were designed to ensure reliable and reproducible operation. These steps included welding the pleat ends, forming around the core, and inserting the material into the final housing.