enveloping / wrapping & stacking technology
machines for lead-acid starter batteries
automotive envelopers
Our enveloping machines and wrapping machines are known for their exceptional performance. Here is our portfolio for automotive, motorcycle and industrial battery assembly.
vertical feeding
BMR 10
enveloped plates/min (for PE) 80 - 160
wrapped plates/min (for AGM) 80 - 140
AGM, PE, leaf-type separator
vertical feeding
BMR 10 H140
For up to 140 PE envelopes and/or 140 AGM wraps/min., processes elements up to 144 mm thick
horizontal feeding
BMR 15X
enveloped plates/min (for PE) up to 170
wrapped plates/min (for AGM) up to 140
horizontal plate feeding with
automatic cell repair function
horizontal feeding
BMR 15X STB
enveloped plates/min (for PE) up to 170
wrapped plates/min (for AGM) up to 140
horizontal plate feeding with
automatic cell repair function
fully integrated stack brake system
horizontal feeding
BMR 15X TT
enveloped plates/min (for PE) up to 340
wrapped plates/min (for AGM) up to 280
horizontal plate feeding with
automatic cell repair function
horizontal feeding
BMR 15X TT STB
enveloped plates/min (for PE) up to 340
wrapped plates/min (for AGM) up to 280
horizontal plate feeding with
automatic cell repair function
fully integrated stack brake system
motorcycle enveloper
vertical feeding
BMR 10 Micro
for up to 100 wrapped plates/min.
for plate heights from 47 to
91 mm
industrial enveloper
vertical feeding
BMR 10/200
For up to 140 PE envelopes and/or 120 AGM wraps/min., AGM, PE, leaf-type separator, processes plates up to a height of 200 mm
vertical feeding
BMV 15/270 Combi
For up to 140 PE envelopes and/or 120 AGM wraps/min., up to 100 leaf-type separated plates, for very soft plates (i.e. pure lead) with heights up to 292 mm and 125 mm stack height
horizontal feeding
BMR 15X IND
For up to 120 PE envelopes and/or 120 AGM wraps/min., for very soft plates (i.e. pure lead) with heights up to 270 mm and 145 mm stack height
horizontal feeding
BMR 15X IND STB
For up to 120 PE envelopes and/or 120 AGM wraps/min., for very soft plates (i.e. pure lead) with heights up to 270 mm and 145 mm stack height, including stack breaker
horizontal feeding
BMR 15X TT IND
For up to 240 PE envelowpes and/ or 240 AGM wraps/min., for very soft plates (i.e. pure lead) with heights up to 270 mm and 145 mm stack height
horizontal feeding
BMR 15X TT IND STB
For up to 240 PE envelowpes and/ or 240 AGM wraps/min., for very soft plates (i.e. pure lead) with heights up to 270 mm and 145 mm stack height, including stack breaker
automatic separator handling
increase machine availability with automated separator roll handling
In lead-acid battery manufacturing, separator rolls can run out every 10–15 minutes, depending on production speed and material consumption. Traditionally, each roll change requires machine downtime and manual operator intervention to replace the empty roll before production can resume.
With its new Automatic Separator Handling concept, BM-Rosendahl takes battery manufacturing automation to the next level. Designed for battery enveloping machines, the solution minimizes production interruptions, reduces manual handling and supports a more continuous, efficient manufacturing process.
The concept consists of two automation stages that can take separator handling from automated material feeding to fully automated roll replacement.
taking battery manufacturing automation to the next level
Automatic Separator Handling is another step towards more efficient, continuous and increasingly autonomous lead-acid battery production.
stage 1
automatic separator feed system
The Automatic Separator Feed System uses two separator rolls installed on the enveloping machine. While one roll actively supplies separator material to the production process, the second roll is positioned as a buffer.
As soon as the active roll runs out, the system automatically switches to the second roll, allowing production to continue without a conventional splicing process.
No conventional splicing.
No glue.
No adhesive tape.
One of the key advantages is that production no longer depends on an operator being available at precisely the right moment to replace an empty separator roll.
Instead, the empty roll can be replaced afterwards, while the machine continues running with the second roll.
This provides several benefits:
- Increased machine availability
- Fewer production interruptions
- More continuous material feeding
- Greater flexibility for production operators
- Reduced dependency on manual intervention
The Stage 1 system can also be integrated into existing machines as a retrofit solution, requiring only approximately 400 mm of additional machine length.
stage 2
automatic separator roll change
The next stage takes automation even further.
A robot automatically picks up new separator rolls directly from pallets and loads them onto the uncoiling station. This eliminates the need for operators to manually handle and lift heavy separator rolls.
By automating the entire roll replacement process, the system further reduces operator involvement, improves workplace ergonomics and supports a higher level of production autonomy.
The BM-Rosendahl Automatic Separator Handling concept delivers advantages beyond simply reducing roll change times:
- Higher machine availability: Minimize interruptions caused by empty separator rolls.
- Reduced manual intervention: Automate repetitive separator roll handling tasks.
- Improved workplace ergonomics: Reduce manual lifting and physically demanding activities.
- Reduced exposure to glass fibre dust: Minimize direct operator involvement in separator roll handling.
- Flexible separator compatibility: Suitable for AGM and PE separator materials.
expertise
Our goals: reduced lead emissions and low scrap rates!
Whether it‘s a vertical or horizontal plate feeder, our technology stands out in perfectly handling also specially coated plates, ensuring a smooth and efficient operation with reduced lead emissions. Our 90° lug brushing system, integrated in most of our enveloping machines prevents twisting of the lugs of soft plates and enables better cast-on quality.
With our enveloping/wrapping & stacking machines you can produce elements for all SLI (starting, lighting, ignition) batteries.
The compact and modular design makes it possible to process AGM, PE, and leaf-type separators.
technical components
Our production equipment combines many technical components which are essential for perfect elements, such as:​
- high-speed plate feeder
- lug brushing
- servo cutting system
- double plate detection
- stacking wheel
- self-cleaning filter unit
- operator panel (icon-based, multi lingual, recipe management, etc.)
- and many more
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