Discover how BW Converting combines engineering expertise with enhanced automation to deliver pioneering products
Part of the global Barry-Wehmiller organization, BW Converting (BW) delivers converting machinery and solutions across multiple industries. The company unifies six historic brands: Paper Converting Machine Company (PCMC), Winkler+Dünnebier (W+D), Baldwin Technology Co., Hudson-Sharp, STAX Technologies, and Northern Engraving and Machine. Since coming together in 2023, they represent quality and innovation across industries including hygiene and personal care, tissue, print, packaging, textiles and nonwovens.
With key product categories comprising of converting machinery, coating and surface treatment systems, packaging and end-of-line automation and digital printing presses, BW continues to launch new and innovative products. Group President, Stan Blakney, joins Manufacturing Today to tell us more about BW’s mission, recent investments and exciting technological advancements. “Our tagline, ‘Change for the Better,’ reflects the duality in our mission,” he begins. “The equipment we develop transforms raw materials into finished goods that benefit humanity but also aligns with Barry-Wehmiller’s purpose-driven approach that measures success by the way we touch the lives of people. Being incorporated within that global enterprise means we share values, common systems and collective expertise, a structure which provides distinct competitive advantages – with a presence in over 100 countries, we have increased reach and resources. Additionally, this alliance combines over a century of collective engineering knowledge, people-centric leadership, cross-industry innovation and financial stability.”
Innovation, automation, and sustainability
Recently, BW launched a truly revolutionary product called TexCoat G4, bringing sustainability to the textile industry by replacing large baths of chemical waste with minute amounts of precision-sprayed chemicals. “TexCoat G4 utilizes a non-contact textile finishing system that enables high spray intensity and deep impregnation, even on thick fabrics,” explains Stan. “The exact amount of chemicals required is consistently and uniformly sprayed across the textile surface and applied only where needed – it has led to dramatic resource savings, most notably a 50 per cent decrease in water consumption, 50 per cent less energy required for drying and zero chemical waste during job changeovers. The combination of reduced energy, water, and chemical consumption with zero waste ensures both a sustainable and financially beneficial textile finishing process.”
Not only has it introduced TexCoat G4 to the textile industry, but the group has also founded several ground-breaking tissue converting innovations. Plystream+™ delivers up to 45 per cent energy savings while retaining maximum web bulk, while SmartTouch© HMI and Go2Roll™ Digital Assistant are available on both Forte and Paragon lines for enhanced operator experience. “We’ve also released our new fusion press,” adds Stan. “Our PCMC Fusion Series CI Flexographic Press represents the next generation of central impression press performance for flexible packaging. It features TruePrint™ auto impression and register, fast changeovers with five-minute deck changes, SteadyPrint enhanced deck stability design for bounce and vibration control, capability to print all ink systems and speeds up to 2,000 fpm.
“Furthermore, we’ve significantly invested in our Packaging Innovation Center in Green Bay, Wisconsin, which serves as a central resource for training, collaboration, and live equipment demonstrations. This facility allows customers to see our technologies in action and provides hands-on training in a real production environment. We’re also accelerating our presence in high-growth regions, particularly Latin America, Asia Pacific, and Eastern Europe, where tissue production is expanding rapidly. We’re developing flexible product designs and adaptable technologies that can deliver consistent quality while respecting local standards and preferences.”
Alongside new products and global expansion, BW has been harnessing automation and digitalization, including the use of digital assistants like Go2Roll™ to reduce training time and operator requirements. “AI represents a significant opportunity to enhance both our customer support capabilities and the performance of our equipment,” Stan highlights. “We’re taking a strategic, phased approach to AI implementation that focuses on delivering tangible value to our customers and we’ve implemented AI-powered troubleshooting assistants. This technology accelerates response times for customer inquiries, enables faster technician onboarding, captures knowledge in a more accessible format and ensures consistent support quality, regardless of technician experience level. In addition, we’re deploying AI-based image classification within our product lines that utilize camera systems; this will detect product defects with greater speed and consistency than manual inspection. Finally, we’re leveraging AI to identify anomalous patterns in operational data from our equipment, analyze sensor data in real-time and anticipate issues before they impact performance which reduces unplanned downtime and extends equipment life.”
Following successful automation initiatives, BW is now integrating sustainability by combining eco-friendly materials, simplified processes and intuitive systems. In 2026, it aims to invest in converting equipment with exceptional web handling and robust process control to work with recycled paper, ultra-low grammages, and new structured substrates. Stan reveals additional plans for the year ahead: “The business landscape is evolving rapidly with major international mergers, shifting tariffs, and region-specific developments like EUDR environmental regulations in Europe. We’re focused on helping our customers navigate these changes with flexible, efficient solutions. We’re also prioritizing technologies that deliver enhanced operator safety, optimized fiber and material usage, minimized waste, faster changeovers and higher output. Our next-generation technology deployment consists of our latest innovations – Paragon winding, Plystream+™, Ventus interfolders with No-Wear Technology, and Invisible-O coreless solutions. With tissue production accelerating in diverse regions, we’re focusing on developing technologies that can adapt to distinct standards, cultural preferences, and economic conditions while maintaining consistent quality.
“In five years, we envision being the undisputed leader in sustainable, efficient converting solutions across all our markets,” he finishes. “Our R&D efforts are driving toward next-generation converting solutions that enable greater web bulk while maintaining tensile strength and softness, all with a fraction of the energy currently required. We will continue to scale our global market position, fully integrate our equipment into Industry 4.0 manufacturing environments and expand our Packaging Innovation Center model to create regional hubs and strengthen our lifecycle support capabilities. Following Barry-Wehmiller’s ‘Truly Human’ leadership principles, we’ll continue building a culture where team members feel valued, leading to superior innovation and customer service that sets us apart in the marketplace.”
