Automated Roller Manufacturing, Roll Covering, Extrusion Process
What this is Automated Roller Manufacturing?
Advanced method for covering rollers with rubber
Who this is for:
Paper, film and foil coaters and laminators
Tissue and towel embossing lines
Corrugated box and folding carton plants
Wood and lumber processing lines
Steel, aluminum and red-metals processing lines
What problem this solves:
Virtually eliminates the problems most often associated with the wrapped, layered (calendered) method of roll covering using thin sheets of rubber wrapped around the roll core
The extrusion process prevents entrapped air cells and blisters creating localized low spots
Reduces process variability and enables consistency in repeat orders
Enhances the rubber-to-core bond between the rubber covering and the roller core, because the rubber is applied under pressure to the bare core
Filters out most foreign particles or contaminants in the rubber during the extrusion process
Allows tougher rubber compounds to be applied to the roller that would otherwise not be suitable using the calendered method
Why this is special:
Creates a homogenous, monolithic roll covering after the rubber is vulcanized
Availability, and when it can be delivered:
Standard product; Imperial Rubber has two automated roll builders which provide scheduling flexibility to meet your needs
Capable of covering rolls to 60 inch diameter and 300 inches in length
Emergency services available
Comparison to competitive products:
The conventional calendered method of roll covering frequently entraps air in the layers causing localized low spots that may appear only when the roll is placed in service. The extrusion system virtually prevents this from occurring by virtue of it’s method of application.
Rubber applied to the roll core using the calendering process cannot be filtered thus leaving contaminant particles in the roll. These may be fall out during roll use leaving pin holes in the roll surface.
Calendered roll covers frequently have significant seam lines that cause problems in coating and laminating processes. These seams are also a point of weakness in the covering if the roll is under a substantial operating load.
Calendered rolls inherently have significant roll-to-roll variability due to the wide variations in manufacturing methods used to apply the rubber. The automated extrusion process provides for a repeatable manufacturing method documented on work order routers providing roll-to-roll and order-to-order consistency.
The calendering process applies the rubber to the roll core at room temperature. However, rubber does not want to adhere to a surface when cool. The automated extrusion process heats the rubber to a process temperature that creates a tacky surface when forced against the roll under pressure by the extrusion applicator head. This promotes a stronger bond between the rubber and the core.
Monolithic roll covering without layers or seams
Improved bonding of rubber to roll core
Contaminant free working surface of roller
Tougher rubber formulations can be used
Coater applicator rolls
Laminating and nip rolls
Ink and water form rollers
Flexo metering and wiper rolls
Gravure impression rolls
Glue and adhesive spreader rolls
Bridle & turn rolls
Squeegee and wringer rolls
Pinch & table rolls
Feed & pull rolls
Wire and felt rolls
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About Imperial Rubber
Imperial Rubber Products manufactures and reconditions rubber rollers, polyurethane rollers, and other precision rolls for converters, manufacturers and commercial printers.
For 25 years Imperial Rubber Products Inc. has earned an international reputation as a high-quality source for new and repaired rollers.
We focus on serving customers with west coast and national footprints who use our rolls in their most demanding applications, where attention to quality matters the most. Printers, converters and manufacturers use our rollers to convert, coat, paint, emboss, laminate, and squeegee. They typically work with primary materials such as paper, plastic, steel, aluminum, wood, glass, nonwovens, and textiles.
We offer considerable product development and custom capabilities, working in an array of materials including rubber, polyurethane, silicone, nylon, Teflon™, Rilsan™, chrome, and copper.
Our processes focus on developing a thorough understanding of your application and delivering what you need, when you need it. Give us a try and you will see why customers tell us they choose Imperial.