# Case Study - Web Guide Upgrade with Roll-2-Roll Web Guide Upgrade Kit > Several aging web guides on converting lines were retrofitted with web guide upgrade kits with the latest technology in web sensing. **Last updated:** 2026-03-07 **Source:** https://r2r.tech/documentation/case-studies/case-study-web-guide-upgrade-roll-2-roll-web-guide-upgrade-kit --- **Document Type:** Case Studies ## Application Web Guide Upgrade Edge Guiding ## Customer Company: Plastic Film Manufacturer in North East US Project Lead: Steven Fiedorczyk - Maintenance Manager ## Customer Problem/Challenge Our customer had several converting lines with web guides running on old and outdated electronics. They were facing complete failure or existing web guides, no spares or support from their current supplier, and complex operation and upkeep. Replacing with new units from the same supplier would still have the issues of complexity and cost of purchasing new web guide systems. web guides it seemed that their only solution was to buy complete web guide systems. The most urgent application required a solution that would allow for center guiding of webs with widths ranging from 40 inches to 80 inches.. ## Our Solution Our sales representative for that region visited their facility and introduced our customer to our technology. The customer knew our sales rep well and had worked with him for many years in the converting industry. After some conversations the customer decided to look at the web guide upgrade kit as an alternative to their problem. After reviewing the characteristics of the actuator (stroke, mountings and thrust), we were able to provide an upgrade system that included two sensors each with a 17 inch range, a controller, a motor driver and an actuator with the appropriate connections to facilitate installation in the existing web guide mechanism. The solution provided a center guiding option that would not require physical repositioning of sensors when faced with width changes and edge detection that did not require calibration of the sensors under changing material or environmental conditions. ![Web Guide Upgrade Kit](https://r2r.tech/sites/default/files/inline-images/Retrofit%20Kit2%20%281%29_1.jpg) ## Results or Customer Satisfaction The first system proved to the customer that this would be a great solution for the rest of their aging web guide systems. They proceeded to purchase additional units to cover a range of web guiding applications with single edge guiding or center guiding on lines processing different web widths. **[Read the customer's testimonial.](https://r2r.tech/testimonials/web-guide-upgrade-kit-application-several-converting-lines)** ## Benefits - Cost Savings - Avoided a costly replacement of web guides, less expensive than other alternatives - Downtime Avoidance - Eliminations of possible complete failure of existing web guides - Operation Cost Reduction - downtime reduction by eliminating reposition of sensors for width changes ## Why the customer chose us? The customer was impressed with the elimination of sensor repositioning. We offered a solution that required less investment and guaranteed operation of the equipment for an extended time. ## Transcript CASE STUDY: Web Guide Upgrade Results or Customer Satisfaction Application The first system proved to the customer that this would Web Guide Upgrade be a great solution for the rest of their aging web guide Edge Guiding systems. They proceeded to purchase additional units to cover a range of web guiding applications with single Customer edge guiding or center guiding on lines processing different web widths. Read the customer's testimonial. Company: Plastic Film Manufacturer in North East US Project Lead: Steven Fiedorczyk - Maintenance Manager Customer Problem/Challenge Our customer had several converting lines with web guides running on old and outdated electronics. They were facing complete failure or existing web guides, no spares or support from their current supplier, and complex operation and upkeep. Replacing with new units from the same supplier would still have the issues of complexity and cost of purchasing new web guide systems. web guides it seemed that their only solution Benefits was to buy complete web guide systems. ➢ Cost Savings - Avoided a costly replacement of web guides, less expensive than other The most urgent application required a solution that alternatives would allow for center guiding of webs with widths ➢ Downtime Avoidance - Eliminations of possible ranging from 40 inches to 80 inches.. complete failure of existing web guides ➢ Operation Cost Reduction - downtime Our Solution reduction by eliminating reposition of sensors Our sales representative for that region visited their for width changes facility and introduced our customer to our technology. The customer knew our sales rep well and had worked Why the customer chose us? with him for many years in the converting industry. After The customer was impressed with the elimination of some conversations the customer decided to look at the sensor repositioning. We offered a solution that required web guide upgrade kit as an alternative to their less investment and guaranteed operation of the problem. equipment for an extended time. . After reviewing the characteristics of the actuator (stroke, mountings and thrust), we were able to provide Products Involved an upgrade system that included two sensors each with a 17 inch range, a controller, a motor driver and an actuator with the appropriate connections to facilitate installation in the existing web guide mechanism. The Web Guide Upgrade Kit solution provided a center guiding option that would not require physical repositioning of sensors when faced with width changes and edge detection that did not require calibration of the sensors under changing material or environmental conditions. Roll-2-Roll Technologies LLC, 1110 S Innovation Way Dr, Stillwater, Oklahoma 74074 Phone # +1-888-290-3215, Email: sales@r2r.tech Website: https://r2r.tech ## Downloads - [Case Study - Web Guide Upgrade (1).pdf](https://r2r.tech/sites/default/files/2021-09/Case%20Study%20-%20Web%20Guide%20Upgrade%20%281%29.pdf) ## Related Products - Upgrade Kit - SCU5 - Web Position Sensor **Tags:** Upgrade Kit, SCU5, Web Position Sensor --- ## About Roll-2-Roll Technologies Roll-2-Roll Technologies LLC, headquartered in Stillwater, Oklahoma, manufactures patented fiber-optic web position sensors and web guiding systems for roll-to-roll manufacturing. Products include ODC edge sensors (48mm to 960mm), 1DC all-in-one sensors, SCU-series controllers, and complete web guide systems. - Website: https://r2r.tech - Phone: +1 (888) 290-3215 - Email: sales@r2r.tech