The Bartell Festoonless Modular Wire Hexagonal Bead Winding System is a fully automatic bead building machine designed to simultaneously produce 1 through 7 single wire beads.

• Nominal Bead Range 13” – 25” (330 – 635 mm)
• 0 Degree Through 15 Degree Bead Base
• Single or Multi-Point Crossover
• Extruder Head Pressure Control
• System Diagnostics

• Single Operator Control
• Hexagonal or Square Section Beads
• Integrated Line Control
• Multi Bead Recipe Storage
• Automatic Unload
• Simple Machine Set-up
• Radial Expand Former
• System Diagnostics
• High Productivity
• Easier Machine String-Up
• Optimized for Quick Changeover

• Minimal Manpower Requirement
• Product Flexibility
• Controlled Process
• Reduced Downtime
• Continuous Production
• Reduced Downtime
• Multi Size Bead Diameters
• Reduced Downtime
• Reduced Bead Cost
• Reduced Downtime
• Increased Productivity

Line Speed: 750 ft/min (228m/min)

The system is controlled via a flat screen operator interface unit capable of accepting bead profiles that can be varied to suit individual customer requirements. Once initial size adjustments are complete, the machine operates in automatic mode.


• A SWS Hexagonal Bead Winder constructed from a machined fabricated steel body housing both the former and payon drive motors (A.C. brushless servos). The winder is capable of winding beads from 13” to 25” diameter having sixteen (16) layers deep and 32mm wide. The wire cutter, positioned at the end of the pay-on wheel assembly, enables the roll down of the cut wire onto the finished bead. At the start of the next bead cycle, the wire is pushed forward into the former grips via a wire advance mechanism.

• A pneumatically actuated auto bead unloading system that removes each bead set while maintaining the same spacing and deposits them into a bead collector chute. Beads may also be unloaded onto an optional bead storage carrousel.

• A 2” cold feed, plastiscrew extruder, having a L:D ratio of 10:1, controlled by a 20 HP AC variable speed drive, fitted with a “vent” insulating head.

• The optional wire preheater is a free-standing self-contained unit, designed to improve “green” rubber-to-wire adhesion by reducing thermal shock at the extruder insulating head.

• Let-off Equipment, comprised of power driven heavy duty let-off stands suitable for handling 1000 lb. reels of wire. They are driven by a 7.5 HP AC drive system capable of accelerating and decelerating the reels of bead wire to match the winder demand.

• Cabinets housing the system control (Allen-Bradley, Mitsubishi or Siemens) servo drives.

The Festoonless Modular is designed to provide customers with a low cost entry into bead building. The machine is designed to build one bead at a time, but can be upgraded to 2, 3, 4, 5 or 6 wires over time to increase productivity without having to purchase a whole new machine.

To upgrade the machine to more wires, the customer would purchase 1, 2, 3. 4 . or 5 more driven let-offs, sheaves for the guide roll stand and spreader, new dies and baffles for the extruder, pay-on/cutter/wire advance assemblies, new unloader fingers and new former shoes. Preheater would require upgrade depending on number of wires used.

The single wire bead building system revolves around a hexagonal bead due to the method of construction. A rubber coated single wire is wound around a nominal diameter (adjustable +/- 0.125”) former and stepped to lay side-by-side upon completion of each convolution to form a layer. At the end of the first layer, the wire is stepped in the reverse direction, which causes it to sit in the troughs/valleys of the wires below. Using these methods, regular hexagonal beads can be produced that conform to the specifications below:


Bead ID: ± 0.005” (0.13 mm)
Bead Width: ± 0.015” (0.38 mm)Bead
Bead Height: ± 0.030” (0.76 mm)Bead
Bead Base Width: ± 0.010” (0.25 mm)


Bead ID: 13-25” (330-635 mm)
Bead Width: Up to 16 wires 1.0” (25.4 mm)
Bead Height: Up to 16 layers 0.75” (19 mm)
Bead Base Angle: 0°-15°
Bare Wire Diameter (max.) 0.072” (1.8 mm)
Bare Wire Diameter (min.): 0.037” (0.94 mm)
Insulated Wire Diameter (max.) Bare wire + 0.010” (.254mm)


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