Web Cleaning Systems — CyClean, VacClean, TakClean & RoClean

Web cleaning is the removal of particulate contamination from the surface of a moving substrate (film, paper, foil, board, textile) before it enters a critical process. Contamination on a web causes print hickeys (spots in solid colour areas), coating failures (pinholes and fish-eyes), lamination delamination (particles prevent bond formation), and seal failures in food and pharmaceutical packaging — any of which can result in product rejection or recall. Four web cleaning methods exist: 1) Fan-driven non-contact (CyClean) — CFD-optimised airflow lifts particles without touching the web. 2) Fan-driven contact (VacClean) — elastomer rollers physically capture particles with vacuum extraction. 3) Tacky roller (TakClean) — adhesive sheets trap fine particles on contact. 4) Ionised air blowers — neutralize static charge to release electrostatically held particles for extraction.

Non-contact web cleaning (CyClean) uses CFD-optimised airflow to disrupt the boundary layer of air traveling with the web, lift particles from the surface, and extract them through vacuum — without any physical contact with the substrate. This is the preferred method for sensitive substrates: coated films, printed surfaces, optical-grade materials, and any web that would be damaged or marked by roller contact. Maximum web speed: 800 m/min. Contact web cleaning (VacClean, RoClean, TakClean) uses physical rollers or brushes that touch the web surface. VacClean combines ionization, elastomer contact rollers, and vacuum extraction. TakClean uses adhesive sheets to trap fine particles. RoClean uses rotating brushes with ionization. Contact systems clean more aggressively and are used for robust substrates: uncoated paper, cardboard, textiles, metal foils. VacClean operates at up to 1,600 m/min.

Maximum operating speeds depend on the cleaning technology: CyClean (non-contact): 800 m/min. VacClean (contact, elastomer rollers): 1,600 m/min. TakClean (tacky roller): 250 m/min. RoClean (rotating brush): 500 m/min. These are tested maximum speeds under standard conditions. Higher speeds may be achievable depending on web tension, substrate type, and contamination level — contact your Animat distributor for application-specific confirmation. In practice, the speed limitation is rarely the web cleaner itself but the relationship between cleaning effectiveness and particle residence time: faster webs mean particles pass through the cleaning zone more quickly, which may require multiple cleaning stages.

Substrate sensitivity is the primary selection criterion. Sensitive substrates (coated films, printed surfaces, optical materials, thin foils) require CyClean non-contact cleaning — no physical contact means no risk of marking, scratching, or distortion. For webs positioned around rollers or with low tension, choose CyClean-R. Robust substrates (uncoated paper, cardboard, textiles, metal foils) can use VacClean or TakClean contact cleaning for deeper particle removal. For battery electrode foils and cleanroom applications, RoClean provides brush-based cleaning with ionization. For heavy contamination combined with fine particles, combine VacClean then TakClean in sequence — VacClean removes bulk contamination, TakClean captures remaining fine particles. Not sure which system fits your application? Our Meech-trained specialist assesses your substrate, speed, and contamination level during a free on-site visit.

Yes — combining web cleaning systems is a proven strategy for achieving the highest cleanliness levels. The most common combinations: VacClean + TakClean — VacClean removes bulk contamination (large particles, fibres, dust), then TakClean captures remaining fine particles with adhesive contact. CyClean + ionizing bars — ionizing bars neutralize static charge upstream, releasing electrostatically held particles, then CyClean lifts and extracts them. This combination produces a charge-free, particle-free web. VacClean + CyClean — contact cleaning for heavy contamination followed by non-contact finishing for sensitive downstream processes. Meech engineers design bespoke multi-stage cleaning solutions based on your specific substrate, contamination type, web speed, and quality requirements.

The Air Handling Unit (AHU) provides the vacuum and suction that extracts particles from the web cleaning heads. Without an AHU, particles lifted from the web surface would simply redeposit. Meech offers three AHU sizes: Mini — 1 pump, dimensions 520 x 300 x 450 mm, 68 dBA. Compact — 2 pumps, dimensions 925 x 450 x 450 mm, 69 dBA. Standard — 3 or 6 pumps, dimensions 925 x 750 x 750 mm, 72-78 dBA. All models operate below the 85 dBA upper exposure action limit, so no hearing PPE is required. The AHU contains replaceable filter bags that capture extracted particles — replace every 6-12 months depending on contamination levels. The AHU display alerts at 75% filter capacity and again at maximum capacity. Ducting between the AHU and cleaning heads should not exceed 5 m total length, with 40 mm diameter runs limited to 2 m maximum.

Web cleaning system noise is determined primarily by the AHU, not the cleaning heads themselves. AHU noise levels by model: Mini (1 pump): 68 dBA. Compact (2 pumps): 69 dBA. Standard 3-pump: 72 dBA. Standard 6-pump: 78 dBA. The cleaning manifolds (CyClean, VacClean, TakClean heads) are quieter than the AHU in all configurations. All Meech web cleaning systems with AHU operate below the 85 dBA upper exposure action value defined in noise exposure regulations — this means no hearing protection PPE is required for operators working near the equipment under normal conditions.

Maintenance requirements differ by cleaning technology. Fan-driven systems (CyClean, VacClean): minimal maintenance. Check and replace AHU filter bags every 6-12 months (the AHU display monitors filter loading and alerts at 75% capacity). TakClean (tacky roller): replace adhesive sheets based on contamination level — typically each shift or between print runs. Adhesive sheet rolls are available in standard and high-tack variants. Replace elastomer rollers approximately every 6 months. RoClean (rotating brush): periodically clean ionization pins to maintain static elimination performance. Replace filters per AHU schedule. For all systems: keep ducting connections tight, inspect vacuum hoses for kinks or blockages, and verify that web tension is consistent across the cleaning zone.

For VacClean contact cleaners, the faceplates must be positioned approximately 1 mm from the taut web. The AHU suction pulls the web into contact with the elastomer rollers — no mechanical pressure is applied. The web must be in free air, away from rollers, conveyors, or the machine bed, so that suction can draw it into the cleaning zone. Any installation angle is acceptable (horizontal, vertical, inverted). For double-sided cleaning, stagger opposing manifolds with a minimum gap of 80 mm apart along the web path to prevent the two suction zones from interfering with each other. Correct positioning is critical: too far from the web and suction cannot draw it into contact; too close and the web may jam or crease.

Yes. The Meech2PLC expansion box enables full remote control and monitoring of web cleaning systems from your line's existing PLC or SCADA system. Supported communication protocols: EtherNet/IP, EtherCAT, Modbus-TCP, Profibus DPV1, and Profinet. Through Meech2PLC, the PLC can start/stop the AHU, monitor filter status, and receive fault alerts without operator intervention. For RoClean systems, the AHU touchscreen also displays brush speed and direction, allowing operators to verify cleaning parameters at a glance. PLC integration is particularly valuable on automated packaging and converting lines where the web cleaner must synchronize with line start/stop, speed changes, and product changeovers.