Rolls for the rubber and plastic industry

Rolls are a central success factor for a profitable production of strip and foil goods made of plastic and rubber mixtures

Detail of a plastic calender roll IRLE rolls are used in the following rolling mills of the rubber and plastic industry: in crushing roll mills, refining mills and mixing mills, in reverse roll coaters and in calender roll mills.

The properties of the rolls for the plastic and rubber industry have to be adjusted to the respective application conditions. The following important points must be heeded:

breaking strength from journals and core material
thermal conductivity
surface quality and wear resistance of the roll barrels
machining of
- barrels and journals
- barrel shape
- surface quality
- cold- and warm concentricity values

The production success of the whole plastic- and rubber production using rolling processes depends upon the perfect quality of these properties and last but not least the marketability of those plastic and rubber products.

Additional content

Roll materials

The suggestions of roll qualities for the following applications are in accordance with the general experience and manufacturing possibilities of WALZEN IRLE.

Alternative suggestions hereto are orientated on the specific operating conditions or from the customers experience.

Crushing roll mills (anvil rollers)

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K30-480	460-500	64-68	693-717
K30-520	500-540	68-71,5	717-738
SP-440	420-460	59,5-64	665-693
SP-480	460-500	64-68	693-717

Refining mills

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K30-440	420-460	59,5-64	665-693
K30-480	460-500	64-68	693-717
SP-440	420-460	59,5-64	665-693
SP-480	460-500	64-68	693-717

Mixing mills

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K30-480	460-500	64-68	693-717
K30-520	500-540	68-71,5	717-738
K30-560	540-580	71,5-75	738-758
SP-480	460-500	64-68	693-717
SP-520	500-540	68-71,5	717-738
CR25-520-C-S	500-540	68-71,5	717-738
CR25-560-C-S	540-580	71,5-75	738-758

Reverse roll coater

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
SP-480 (verchromt)	460-500	64-68	693-717
K40-520	500-540	68-71,5	717-738
K40-560	540-580	71,5-75	738-758

Gasket sheet calender

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K40-520	500-540	68-71,5	717-738
K40-560	540-580	71,5-75	738-758

Rubber calender

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K40-520 / K50-520	500-540	68-71,5	717-738
K40-560 / K50-560	540-580	71,5-75	738-758
CR25-560-C-S	540-580	71,5-75	738-758
CR25-600-C-S	580-620	75-78,5	758-777
FS1-560	540-580	71,5-75	738-758
FS1-600	580-620	75-78,5	758-777

Plastic calender

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
K40-520-V-S / K50-520-V-S	500-540	68-71,5	717-738
K40-560-V-S / K50-560-V-S	540-580	71,5-75	738-758
K40-600-V-S / K50-600-V-S	580-620	75-78,5	758-777
CR35-600-C-S	580-620	75-78,5	758-777
CR35-640-C-S	620-660	78,5-82	777-793
CR35-680-C-S	660-700	82-85,5	793-807
CR35-600-C-ST	580-620	75-78,5	758-777
CR35-640-C-ST	620-660	78,5-82	777-793
CR35-680-C-ST	660-700	82-85,5	793-807
FS1-520	500-540	68-71,5	717-738
FS1-560	540-580	71,5-75	738-758
FS2-600	580-620	75-78,5	758-777
FS2-640	620-660	78,5-82	777-793
FS2-680	660-700	82-85,5	793-807

Melting calender

WALZEN IRLE-Quality	Surface hardness
	HV	°SHC	L_D
CR35-600-C-ST	580-620	75-78,5	758-777
CR35-640-C-ST	620-660	78,5-82	777-793
FS2-600	580-620	75-78,5	758-777
FS2-640	620-660	78,5-82	777-793

Surface quality

The surface quality of the rolls is decisive for the products to be produced.

RT, RZ and RA are the most common measurements to describe the surface quality of rolls.

The quality of the roll surface must be renewed by re-grinding when the usage causes wear.

WALZEN IRLE provides re-grinding service with short delivery times, according to the demands on the surface quality, shape, cold- and warm concentricity.

The measuring results of the surface quality, the barrel shape, and the cold- and warm concentricity accuracy will be verified in an extensive test certificate.

Chart "Grinding Qualities"

Innovation

S-Technology

Improved thermal transfer of highly stressed thermo rolls in plastic calender rolls

The impulse to apply the S-technology was initiated by the target to achieve profile optimisation and better heat transfer of high load thermal rolls in plastic calenders. The roll type DuoTherm^® S based upon the flow through principle "Duopass", but furthermore it has a helix in the peripheral borings. The helix gives the heating medium a twisted flow, which balances out the loss in temperature over the roll width. The twisted flow has a positive effect on the heat transfer between the heating medium and the inner wall of the peripheral boring.

The use of a helix with a continuously reduced increase in the flow direction allows, for the first time, the temperature loss to be balanced out, without influencing the roll fluid pressure parameters considerably.

Therefore this technology has a positive effect on the geometrical shape of the roll. The roll type DuoTherm^® S can also be operated with reduced volume flow, without having to make significant concessions on the profile quality.

Even better results can be achieved using the roll type MonoTherm^® S, a roll which is flown through by the Monopass-system and which is equipped with helix applications to compensate the axial temperature differences. The roll types MonoTherm^® S and DuoTherm^® S, developed by WALZEN IRLE, offer enough potential to fulfil the requirements of a modern plastic calender.

The WALZEN IRLE identification of the thermal rolls with S-technology are:

The thermal roll identification MonoTherm^® S 200 reproduces the flow through principle Monopass, the application of the S-technology and the roll surface temperature of 200°C.