Founded in 1999 and based in Bedford, Alpha Converting has built a reputation as a trusted manufacturer of precision-engineered converting machinery. From slitter rewinders to spoolers and winders, the company delivers tailored, high-performance solutions that serve industries worldwide.
Now celebrating 25 years of success, Alpha continues to lead with British-built quality, responsive customer service, and a passion for solving complex challenges in the converting sector.
Interview with Matthew Wilson, Managing Director & Analisa Fernandez, Technical Sales Engineer at Alpha Converting Equipment
What are the main areas of activity of the company?
Matthew Wilson & Analisa Fernandez: The converting market focuses on transforming raw materials—such as paper, film, foil, and nonwovens—into finished rolls or sheets for packaging, printing, or further industrial use. Alpha Converting plays a key role by supplying advanced machinery, including slitter rewinders, spoolers, and winders, that enable high-speed, high-accuracy processing.
As customer demands for customization, automation, and sustainability increase, the market continues to evolve. Alpha reflects these trends by offering tailored solutions that enhance efficiency, productivity, and quality.
What’s the news about new products/services?
M.W & A.F: We have expanded our scope beyond slitting and rewinding to deliver fully integrated, automated solutions. This includes auto unloading, palletizing, wrapping, data control, and traceability—effectively streamlining operations from raw material input to palletized rolls ready for shipment. The result is increased uptime with reduced staffing requirements.
At the same time, we are introducing more flexible, customer-focused service packages. These include on-site support from dedicated engineers, customized spare parts packages to minimize lead times, remote diagnostics, scheduled maintenance, and tailored technical training for in-house teams.
In addition, we’re supporting customers with reconfiguring production environments—optimizing layouts, relocating machinery, ensuring compliance with the latest safety standards, and refurbishing existing equipment to extend lifespan. With our technical expertise, Alpha is well positioned to deliver this next level of support.
What are the ranges of products/services?
M.W & A.F: Automatic Winders (ALPHAMATIC) are built for high-speed production of short rolls across a wide range of materials from 50 µm LDPE to 10 mm thick foams. These machines feature automatic core loading, tapeless attachment, preset length cut-off, and roll closure via label or tape. They can operate independently or integrate with extrusion and coating lines, offering cycle times faster than many turret rewinders.
Two-Drum Paper Winders (ALPHADRUM) are designed for high-efficiency paper processing. These machines can manage web widths up to 2,800 mm, rewind diameters up to 1,800 mm, and run at speeds reaching 1,500 m/min. They are ideal for large-scale paper converting operations requiring speed and precision.
Trim winders (ALPHATRIM) offer a compact, efficient solution for edge trim removal in high-speed converting lines. Designed for paper, film, and foil, these machines use variable speed motors and closed-loop tension control for consistent winding. With options including quick-release shafts, they reduce noise, dust, and maintenance while improving productivity. Provides a clean, cost-effective alternative to vacuum trim systems.
ALPHASPOOL machines offer two main variants: stand-alone pancake spoolers and slit spooling machines. Pancake spoolers convert narrow rolls into level-wound spools with closed-loop tension control and speeds up to 400 m/min. Slit spoolers combine slitting and spooling, handling widths up to 150 mm with modular design and touchscreen control. Both variants deliver high-precision winding for tapes, films, foams, and filaments, making them ideal for industries like packaging, medical, and electronics.
Slitter, rewinder with duel rewind shafts (ALPHATWIN) delivers high-speed slitting and rewinding for materials like paper, film, and label stock. The twin rewind shaft ensures final product separation.
Our ALPHATWIN HR model handles web widths up to 2000 mm and rewind diameters of 1000 mm minimum, with features like automatic knife setting, laser core positioning, and speeds up to 600 m/min. Designed for precision and efficiency, these machines offer closed-loop tension control, touchscreen operation, and easy roll handling.
Each Alpha Converting machine is tailored to the specific needs of the customer’s production line, based on proven modular designs, that allows seamless integration
What is the state of the market where you are currently active?
M.W & A.F: The market we’re in is growing sustainably, presenting both new challenges and exciting opportunities. With new areas growing as they develop such as biodegradable packaging and battery technology. This is where our ability to adapt and customise puts Alpha Converting above our rivals. Traditional sectors are showing a level of shorterm uncertainties requiring more justification in equipment replacements where our focus on efficiency and lower levels of operator interaction supports investment.
In 2023, the global converting equipment market was valued at $40.87 billion, rising to $43.01 billion in 2024, with a CAGR of 5.2%. By 2025, projections place the market at $45.22 billion, maintaining consistent growth. Looking further ahead, forecasts suggest a market size of $54.38 billion by 2029, reflecting a CAGR of 4.7%.
What can you tell us about market trends?
M.W & A.F: The converting industry is experiencing steady growth, and we are seeing that growth reflected in our own operations as well.
Trends we have noted:
- The rise of e-commerce is expanding the flexible packaging sector.
- There is a high demand for flexible electronics
- Sustainability is essential
- Automation is a growing area of interest, and we’re seeing increased demand for it
What are the most innovative products/services marketed?
M.W & A.F: A recent project of ours is the ALPHAMATIC 1300, a cutting-edge design with a phantom axis turret for compact layout and flying splice transfer.
The integration of a printing press directly feeding into a fully automated rewinding and packaging line represents a transformative advancement in production technology. This seamless system eliminates traditional bottlenecks, significantly enhances product quality, and boosts overall output efficiency. Such innovation is only possible through continuous communication between the printing and converting equipment. This real-time coordination enables an uninterrupted flow of material—from raw rolls to finished, palletized products—without the need for intermediate work-in-progress (WIP) stock. By removing WIP, manufacturers reduce labour requirements and free up valuable floor space, optimizing operational efficiency across the facility.
This turnkey state-of-the-art solution is a transformative leap toward operational excellence, positioning manufacturers at the forefront of innovation and success to deliver an efficient system that reduces labour demands whilst ensuring repeatability and maintaining quality.
What estimations do you have for the second half of 2025?
M.W & A.F: We anticipate a steady third quarter, followed by a strong final quarter and early 2026 in terms of capital equipment sales.
Recurring revenue streams—including spare parts, upgrades, automation add-ons, and service contracts—are also expected to grow steadily. In addition, we are exploring new marketing channels to expand our reach, which we expect will translate into increased orders and sustained growth.