5Te Tensioner Level Winder System

A spoolbase facility in Mobile, Alabama, was increasing its manufacturing output and required a handling system that could support a wider range of products while improving spooling accuracy and operational reliability. The existing equipment lacked the traversing performance and product handling flexibility needed to keep pace with these evolving operational demands.

MDL initially carried out a Front-End Engineering Design (FEED) study to assess operational requirements and determine the most cost-effective solution for the facility. Based on the study, MDL designed and delivered a bespoke 5Te two-track tensioner, integrated with a purpose-built level wind traversing system. The system enables handling of flexible products from 50mm up to 450mm in diameter, with the integrated level wind providing controlled bi-directional traversing across a 5-metre stroke - covering the full width of a typical installation reel. Traversing is achieved through a hydraulically driven screw jack mechanism, with the system operated either from a local control panel or a remote walk-about control box for improved operator visibility and safety.

The new 5Te Tensioner Level Winder System improves the reliability and accuracy of the facility’s spooling operations while enabling the handling of a wider range of products. By providing controlled line tension and consistent traversing performance, the solution supports efficient spooling while protecting product integrity. The integrated design also simplifies operations compared with the previous setup, allowing the facility to increase output while maintaining dependable performance.