fully automatic systems
With its own development and design team, NUCLEUS offers you a wide range of fully and semi-automated machine solutions – individually tailored to your requirements. Our portfolio already includes specialized tube and bag machines, complete splicing units, and special systems for cross-welding processes.
In addition to our manual Rotosonic single workstations, we offer a wide range of automated machine concepts. Thanks to our in-house expertise, we are able to implement almost any desired system—from proven standard solutions to completely customized developments.
Filtration-applications
Adaptive tube production
The tube filter production line enables the fully automated manufacture of filter tubes in various diameters. It includes an unwinder for material up to 800 mm wide and a unit for rotary seam welding.
Depending on requirements, filter tubes can be manufactured with an overlap seam (over 30 or 50 mm tube arms), with an overlap seam including edge trimming, or with a separating seam. Guillotine shears or a laser system are available for precise length cutting.
Specifications
maximum welding speed:
- up to 20m/min
material processing:
- Roll width: up to 800 mm
- Roller diameter: up to 700 mm
Filter tubes that can be manufactured:
- Diameter: 40-250mm
- Length: 80-1000mm
Mini-tube production
The mini tubular filter machine is specially designed for the fully automatic production of small filter tubes. The compact system features a precise material unwinder as well as folding and guide units for optimal material guidance. A welding unit ensures uniform seam connections.
Puller units are integrated to ensure continuous and controlled material transport, while a material buffer keeps the manufacturing process stable. Finally, the cutting unit ensures that the hoses are cut precisely to the desired length.
This machine offers a reliable and space-saving solution for the efficient production of small filter bags with high precision.
Specifications
Maximum welding speed:
- up to 24,3m/min
Filter bags that can be manufactured:
- Diameter: 3-60mm
Medical applications
DX100 | Mouth and nose protection masks (MNM) production
NUCLEUS’ fully automated mouth and nose mask production system enables precise and economical production of up to 160 masks per minute. Depending on requirements, it processes 1–4 layers of material and is fully servo-controlled—without a central drive shaft, using multiple servo motors for maximum accuracy.
The line includes automatic material feeding with nose clip dosing, an ultrasonic welding unit, precise folding stations, and welding units for the ear loops. An INKJET printer allows logos or markings to be printed directly onto the material.
An optional camera system is available for visual inspection and automatic rejection, ensuring reliable quality assurance. Material rolls up to 1200 mm can be processed using the “Maxi” unwinder.
This system combines maximum automation, flexible equipment, and comprehensive process monitoring—for economical and reliable mask production at an industrial level.
Specifications
- max. 160 Masks/min (depending on the equipment)
- 1-4 material layers
- 100% servo-controlled (no central drive axle)
- max. 1200mm Rolls (option „Maxi“-unwinder)
- visual control with automatic rejection (option)
Application example
Home appliances
Pillowcase production
Specifications
- production width: 400–1000mm
- Material feed via self-supporting unwinder
- Ultrasonic longitudinal and transverse welding
- Integrated cross-cutting unit
- Servo-controlled puller unit
- Automatic pallet destacking
Border Slitter | Mattress production
The Border Slitter is a compact inline solution for efficient processing of quilted mattress fabrics. The material is transferred directly from the quilting machine, buffered, and then precisely divided into up to twelve lines, the widths of which can be adjusted manually.
The cut-welding unit operates with 13 ultrasonic welding units that simultaneously cut and seal the lines. Two puller units ensure a consistent material flow, and an optional rewinder completes the process chain. The system is conveniently controlled via a central touch panel.
The system can be integrated into existing lines or operated independently and, with remote maintenance and Industry 4.0 options, offers a modern, reliable solution for mattress production.
Specifications
PanelMaster | duvet production
Ultrasonic welding is becoming increasingly important in the duvet industry. Our machine enables the fully automated production of ultrasonically welded panels and impresses with its maximum efficiency and quality. Longitudinal and transverse seams are precisely cut and welded in a single operation.
Discover the world’s fastest fully automatic production machine for duvets.
Specifications
- Up to 15 m/min (depending on material and size)
- Max. material width 2300mm
- Between 3 and 13 welding units, depending on the application
slatted frame production
The slatted frame production line enables the efficient manufacture of slatted frames that are securely welded with a tape-shaped fabric. The line forms a complete production line and comprises two material dispensers, a NUSonic Eco press, and a unit for welding, cutting, and transporting the material.
Specifications
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Roll width up to 800 mm
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Welding speed up to 20 m/min
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Filter hose diameter 40–250 mm
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Length cutting by guillotine or laser
connecting devices
cross welded joints
The NUCLEUS cross welding device is ideal for applying uniform cross seams. Whether as a single-station, inline version with free material feed, or as a fully automated machine, NUCLEUS will find the right solution for you.
Tape Splice-Unit
The NUCLEUS splice unit is a compact solution for connecting or joining roller conveyors one after the other. The material width and welding process can be adjusted individually.
Specifications
- User-friendly material feed
- Vacuum fixation of the belt
- Adhesive or ultrasonic bonding
Splice-Module
The NUCLEUS splice unit is a compact solution for connecting or joining roller conveyors one after the other. The material width and welding process can be adjusted individually.
Specifications
- Welding widths of 1-6 m possible (other sizes upon request)
- Speeds in the welding process depending on the material
- Material width and welding process can be individually programmed
- Controls can be customized
Examples of ultrasonic welding applications
Your personal sales partner
You can find our sales partners in many countries in Europe and North America. If you have any questions, please do not hesitate to contact us or our sales partners. We also prepare welding samples for you.