Solutions for the Converting Industry

Transcription

1 Solutions for the Converting Industry

2 Converting Rollers & Services Application Engineered for Your Unique Needs The Only Industrial Roller Source You ll Ever Need Menges Roller Company has been serving the converting industry with innovative products and high-value services for over 40 years. This experience gives us the knowledge, skills and insight needed to provide real solutions to real challenges. Menges Roller provides roller products and services that help you run faster, waste less and produce better products. Menges Makes All Types of Rollers Used in Converting Process Rolls of All Types & Sizes Small to Large Rubber Covered Rolls Web Spreader Rolls Feed Rolls Idler Rolls Layon Rolls for Adhesives & Coatings Chill & Heat Transfer Rolls Menges Rollers are a one-step solution to common web handling issues. A variety of highly-effective patterns are available, including herringbone, diamond, fluted serrated and many others. Serving Every Converting Industry Sector Cast Film Packaging Laminating Coating Extrusion Non-Wovens A Important Repair Services for the Converting Industry One of our specialties is large process rollers. Over 18 feet long, this one was sent to us for refurbishing. We recovered with a premium elastomer and repaired the journal shafts. Rollcover Stripping & Recovering with Any Elastomer Core Repair: Regrinding & Polishing Chrome Replating & Finishing (to mirror/any Ra value) Acid Flushing of Heat-Transfer/Chill Rollers Repairing Internal Parts on Heat-Transfer/Chill Rollers Journal Repair & Replacement Two-Plane Dynamic & Static Roller Balancing Grooving & Parabolic Crowning Elastomer Consulting: Compounding & Testing Services Unlike many roller fabricators, Menges has in-house rollcovering capabilities. Our body of knowledge in rollcoverings spans 40 years, so we know what compound to recommend, how to apply it, and how to profile it if necessary for maximum efficiency. Rollcovers Mastering Chemical, Thermal & Physical Properties Menges Roller is a market leader in elastomer development and use. In addition to covering with any formula on the market today, we can blend custom compounds based on your specific requirements. Available Rollcovering Compounds (partial list) Natural Rubber Hypalon Silicon & EPDM Silicon Blends EPPM Nitrile (NBR / BUNA) Neoprene Anti-Static Blends Hypalon Blend for Corona Treatment Uses Viton (Fluoroelastomer) FDA Approved Coverings Thermal Plastic Urethane / Tiger Max

3 Core Manufacturing - The Right Design for Your Application: We provide new replacement cores via reverse-engineering your existing roller or from a drawing or schematic. Menges manufactures thousands of roll cores for OEM and after-market installations to be rubber covered or chrome plated. Our fabrication facility is exceptionally large, as are many of our machines, giving us the capacity to produce precision roller cores as long as 30 feet and up to 48 inches in diameter. Roller Core Materials High-Grade Carbon Steels Aluminum & Aluminum Alloys Carbon Fiber Hardshell Finish & Plating Options Chrome (polished to mirror or any Ra value) Nickel Plated Standard Lathe Finish Grit/Shot Blasted Matte Finish Machine-Cut Grooving Tempered & Case-Hardened Thermal Spray (abrasion & corrosion-resistant coating) Precision-made liveshaft roller cores like these represent one of our key offerings. We manufacture cores up to 30 feet long and 48 inches in diameter - a capability beyond most competitors. Extending Roller Life - Repair & Refurbishing Services Journal Repair & Replacement Regrinding & Re-Plating Diameter Modification for Journals Bearing Race Resurfacing With one of the most complete fabrication facilities in the industry, Menges constructs all roller types: liveshaft, deadshaft, and recessed bore formats, as seen above. Advanced CAD technology is employed to model performance dynamics and generate accurate prints. This heat transfer roller - which serves on a laminating line in a flexible packaging operation - is being cylindrically ground in-house and will be re-plated with mirror-finish chrome. Here with Matt Menges, each of these rollers is over 26 feet long. We made double-plated journal sets capable of withstanding incredible loads. To ensure peak performance on the job, we dynamically balanced these super-sized rolls. Few suppliers can build large rolls to such exacting specifications.

4 Grooving & Serration Services for Converters - Reduce Waste, Increase Uptime, Run Smoother Menges Roller offers a multitude of grooving and serration options, each designed to solve particular problems in the handling and processing of paper, foil and film. These rollcovering & grooving options can be applied to new or refurbished rollers. Combined with the proper rollcovering compound, our precision-machined patterns cause substrates to feed smooth and flat. Our rolls help converters take control of viscous liquids and gelatinous adhesives, making them layon even and thin. So take back control of your web. Speak to your Menges Sales Engineer today and finally solve those persistent problems. MENGES WEB SPREADER: This roll is ideal for smoothing wrinkles in thin-gauge materials such as foils, paper and film. Available in durometers from 25 to 90 Shore A, it s tough enough for continuously running lines. Web spreaders usually run in idler positions, but they can be placed in almost any problem area. We can convert your existing roller to a web spreader or manufacture a new roller with this very effective pattern. MENGES HERRINGBONE Used as not only a web spreader, but also as a feed roller, a Menges herringbone roller is ideal for boardly products such as SPS board, corrugated and other hard to feed/hard to align products. Paired with one of our proprietary rubber compounds it will stand up to your harshest in-feed applications. DIAMOND SERRATION Used for many applications, but most often in flexible packaging, this groove format performs superbly and is used by many OEMs as a layon roller. It has excellent channeling abilities, moving liquids and air away from substrates. FLUTED ROLLER SERRATIONS This roller is used in applications where lateral serrations can be beneficial, such as spreading thicker adhesives and handling rigid or weighty stock. Your Menges Sales Engineer can advise you on which groove pattern would be most effective in solving your particular material handling problem. CIRCUMFRENTIAL SERRATIONS This roller is very effective at aligning substrates for in-feed operations. It allows materials to pass between rollers without being crushed. Menges custom-serrated rollers can be used in pairs and may be strung to eliminate wrapping-up of substrates where webs change direction. Groove and serration work is always enhanced by the proper rollcovering compound. Menges started out as a rollcovering house, so we understand the chemical, thermal and physical characteristics of today s elastomers. We can cover your roller with any compound on the market today - rubber, silicon or urethane-based. Menges can also formulate custom compounds to meet specific requirements. In addition to rubber web spreaders, we make aluminum herringbone web spreaders. Rollcovering for Results Faster Linespeeds Scrap & Waste Reduction Less Down-Time Improved Process & Product Quality We custom-made these roller cores, covered them with our Tiger Max thermal plastic urethane, and then grooved each to perform a specific material handling task. Special Options for Special Needs Acid & Alkali Resistant Compounds Anti-Static Treatments FDA Approved Applications These are for a flexible packaging customer. We made the shafts, covered in Hypalon 65 (durometer Shore A) and grooved with our Menges herringbone pattern.

5 Roll Crowning / Profiling - For Uniform Roller Contact, Contact Menges Roller For rollers used in nip and squeegee applications, crowning can be the single most important factor in determining performance. Crowning counters the effects of roller deflection, which is basically a slight bending in the rollers. In a typical nip system, roller ends tend to make tight contact and squeeze the web material tightly, while the middle section will have airspace or play. Figure 1 demonstrates this clearly. Negative Effects of Non-Crowned Rollers are Easy to See: Uneven Distribution of Adhesives Between Laminate Layers Coatings are Spread Unevenly Poor Web Alignment Downtime Is Increased Rollcoverings Wear-Out Quicker Uneven Nip Pressure All these factors negatively effect operational efficiency, product quality, and your shop s reputation. But Menges Roller can help! Figure 1 - Non-Crowned Rollers in Nipping System In a nipping or squeegee system, if rollers are not crowned, converters can see uneven contact and pressure, resulting in poor laminating and decreased product quality. Menges to the Rescue: Menges Roller utilizes specialized software tied to advanced machinery to create the perfect parabolic profile. Specifying a roller s crown must done cautiously - a few mils (.001 ) can make a huge difference - and Menges Roller is uniquely qualified to handle this complex task for converters. To calculated the proper Cosine Curve, or diametric crown deficiency, we take a number of factors into consideration, including operating load, desired nip pressure, roller specifications and other relevant throughputs. Sometimes called profiling, crowning is a service few fabricators can fulfill and seldom with our degree of accuracy. Figure 2 - A Properly Crowned Rollers from Menges Although this illustration is exaggerated a bit to make the point, a crowned roller will have a parabolic arch, with the angle and size being determined by a range of factors Testing Your Roller s Profile - Nip Impression Paper At Menges Roller, rollers are our lifeblood and passion, which is why we ve developed products to enhance and measure the performance of rollers for the converting industry. Our Nip Impression Paper is a breakthrough product that allows operators to measure the even-ness of nip pressure, visually showing the areas that need crowning. This special paper is inserted into the nipping crimp, where visible impressions are made to show areas of proper nip pressure or where contact is poor, indicating a need for profiling services. Available only from your Menges Roller Sales Engineer, this important product allows you to determine if rolls need to be crowned, reverse crowned, and in which portion of the roll. Balanced is Better Unbalanced rollers can cause damage to bearings and machinery. In some cases, poorly-balanced rolls can damage substrate stock. Menges has invested heavily in sophisticated computer-enhanced alignment and balancing machines. Using this technology, every new roller is static and dynamically balanced, ensuring smooth and true functionality over long-term use. We also offer our balancing services as an ala-carte service, and are happy to balance your existing rolls. You ll see a decrease in vibrations, longer component life and a smoother flow of materials.

6 Advanced Roller Technology for Converters - Chill & Heat-Transfer Rollers Menges is at the leading edge of advanced heating and cooling technology for rollers used in cast film, extrusion, laminating and other converting-related sectors. Sometimes called chill rolls or heat transfer rolls, we design, test and fabricate very specialized double-walled thermal rollers. Menges Thermal Rollers maintain constant temperatures to within +/- 1 F. Heated rolls are often used in gluing or laminating lines: the roller s heat greatly enhances the adhesive properties of glues. Heating materials quickly and evenly, our heat-transfer rolls are typically capable of maintaining temperatures up to 400 F. Chill rolls are primarily used to quickly cool previously-heated materials, saving time vs. waiting for materials to naturally cool. One key application is making materials instantly rigid, essentially decreasing set times after partial melts or extrusion feeds. Although specs, materials and finishes can vary greatly, thermal rollers are typically split into three wide categories: Outer Shell Inner Shell Output of Water or Oil Spiral Baffles Water/Oil Flows In One End and Out the Other End Double-Shell Mono-Flow Configuration: This design allows the heating/cooling liquid to flow in one end and out the other end of the roller. The mono-flow configuration provides outstanding temperature control and our expertise in fabricating these rollers is unsurpassed. Outer Shell Inner Shell Spiral Baffles Rotary Union & Supply Tube Allows Both Input & Output of Coolant from One End Double-Shell Duo-Flow Configuration: The roller core contains a siphon tube and rotary union, through which the heating/cooling liquid flows both in and out. This type of thermal roller offers excellent temperature control, while saving a bit of space on the production floor. Outer Shell Output of Water or Oil Water Circulates as Roller Turns Input of Water or Oil Single-Shell Configuration: Also known as a can design, this economic thermal roller meets basic temperature control needs and is used in non-critical heating and cooling applications. We can engineer and manufacture these rollers to fit your exact size, finish and core specifications. Maintain Thermal Roll Performance - Acid Flushing Chill & heat-transfer rollers that are not performing optimally may be clogged with scaling or mineral deposits, the result of unbalanced water or chemicals. Menges offers a unique acid flushing service that breaks down and flushes deposits of calcium, rust and congealed chemicals. Customers see immediate improvements in thermal transfer performance. This also allows engineers to dial back flow rates; you save energy and increase the lifespan of rollers, pumps and connected equipment. Ask your Sales Engineer about our uniquely effective acid flushing services for your thermal roller. This heat transfer roller performed for many years without acid flushing. Had the service been done, it could have lived a longer life. Menges Roller fabricated this large heat-transfer roller for a major packaging producer. With a double-shell mono-flow spiral-baffle design and a mirror-pocket finish, the roller face is over 9 feet long and 30 inches in diameter. Menges Roller Company Industrial Drive Phone: Application Wauconda, Engineered IL for Your Fax: Unique Needs