Purpose Built Converting Systems,
Special Machine Systems, Custom Web Fed Systems

Bernal specializes in designing and manufacturing custom converting equipment tailored to your specific needs. With over 45 years of expertise, we deliver high-speed, high-efficiency continuous web converting systems for a wide range of products, supporting web widths from 1 inch to 110 inches. We seamlessly integrate our equipment with existing, new, or developmental systems. Our clients include Fortune 500 companies across industries such as packaging, medical, automotive, consumer goods, food products, batteries, disposables, and aerospace.

Why Choose Bernal Rotary Systems?
Bernal systems utilize a wide range of advanced techniques, including die-cutting, punching, ultrasonic and heat sealing, laminating, vacuum transfer, folding, counting, pouching, embossing, heating, chilling, and stacking. Our world-class service department ensures consistent production performance and support for clients across the globe.

Modular Design
Bernal systems are built on a foundation of modular stations, which include both standard and custom-designed components. These modular stations, composed of subassemblies, facilitate quick product changeovers, ensuring flexibility and efficiency for a variety of production needs.

Standard Components
Bernal offers a robust selection of standard components that serve as the foundation for custom system designs. These include bearing housings, die cutting modules, infeeds, unwinds, rewinds, vacuum transfer stations, heat seal stations, delivery systems, and stackers. Our systems are designed to accommodate web widths from 1 to 110 inches and operate at speeds ranging from 10 to 1500 fpm.

Custom Engineered to Meet Your Need

For products adaptable to web processing with multiple cutting and assembly operations, Bernal systems deliver higher productivity and lower unit costs. Whether you need a complete manufacturing system or modular sections to integrate into your existing setup, Bernal provides solutions tailored to your requirements. We specialize in proof of principle, prototype, pre-production, and full-scale production systems.

Operational Bernal Systems

• Batteries

• Can Lids

• EKG Pads

• Abrasives

• Cartons

• Filters

• Bandages

• Snack Foods

• Cooling Fins

• File Folders

• Bags

• Pouches

• Cups

• Cereal

• Alcohol Swabs (Prep Pads)

• And many more…

Electronic Drives & System Control

Bernal incorporates the latest microprocessor-controlled drives, PLCs, production data acquisition, and system controls into our systems. We offer print and part registration software, integrated visual inspection, and real-time quality control systems. Our expertise ensures seamless interfacing with other equipment, delivering system efficiencies as high as 99%.

Features

Bernal systems utilize cutting-edge technology supported by high-tolerance machining, up-to-date CAD / CAM software, and a world-class engineering team. Key features include:

Single-source responsibility
Inspection systems
Food-grade systems
High-precision cutting and assembly
Print and part registration
Precise tension control
Rapid product changeovers
System integration
Compatibility with all die types
Roll-to-roll or roll-to-finished-part processing
Temperature-controlled oil lubrication

Complete System Responsibility

When Bernal designs a converting system, we take full responsibility for the entire process. System designs are reviewed with you before production, assembled and tested at Bernal, and approved for speed and performance before shipping. Our team oversees installation, commissioning, final approval, training, and startup at your facility.

Die Options

As the core of our product line, Bernal rotary dies have proven reliable in countless applications. They are available to cut, sheet, form, emboss, vacuum transfer, heat seal, and ultrasonic seal. Many dies feature removable segments for cutting and embossing in one die, or to vary features across applications. Dies can be changed in as little as one minute and are mounted in precision bearing housings for easy removal during product changes. Depending on materials, die life ranges from 1 to 500 million revolutions.

Why Choose Bernal Rotary Systems?

Bernal systems utilize a wide range of advanced techniques, including die-cutting, punching, ultrasonic and heat sealing, laminating, vacuum transfer, folding, counting, pouching, embossing, heating, chilling, and stacking. Our world-class service department ensures consistent production performance and support for clients across the globe.

Standard Components

Bernal offers a robust selection of standard components that serve as the foundation for custom system designs. These include bearing housings, die cutting modules, infeeds, unwinds, rewinds, vacuum transfer stations, heat seal stations, delivery systems, and stackers. Our systems are designed to accommodate web widths from 1 to 110 inches and operate at speeds ranging from 10 to 1500 fpm.

Modular Design

Bernal systems are built on a foundation of modular stations, which include both standard and custom-designed components. These modular stations, composed of subassemblies, facilitate quick product changeovers, ensuring flexibility and efficiency for a variety of production needs.