OUR FOCUS IS ON RUBBER ROLLS.

Transcription

1 OUR FOCUS IS ON RUBBER ROLLS. AND NOTHING ELSE! Sponge Steel E235 Polyurethan Shore A

2 02 Roll coverings Compound development and production Profiles of any type Complete rolls and component assemblies Regrinding service... and a wide range of additional services. AND EVERYTHING RUNS SMOOTHLY. Our products are optimized for specific fields of application and tailored to customer specifications. We manufacture single pieces, small and large series.

3 03 ROLL COVERINGS WITH ONE TO THREE LAYERS Single-layer: solid Double-layer: solid solid Three-layer: solid sponge solid RECIPE FOR A SUCCESS STORY? Just combine your requirements with our expertise! In our capacity as truly innovative high-performance company, we have continuously grown in line with ever increasing demands. Today, we produce natural and synthetic rolls to customer specifi cation in any quality and quantity on a total production area of over 5,000 m². Already in the development phase, our experienced team of engineers and technicians will give your all the advice and practical support you need. Based on your specifi c requirements, we will defi ne in close cooperation a customized roll specifi cation and manufacture the perfect roll for your application. $ COMPOUND DEVELOPMENT We are prepared to develop special compounds for new applications that comply with your specific operating conditions. $ COMPOUND PRODUCTION We offer more than 500 tried and tested recipes that can be produced in our mixing area at any time. Your benefit: enhanced flexibility and substantially reduced delivery times. $ CUSTOMIZED SOLUTIONS HEFNER rolls are manufactured to customer specification. $ LOAD SIMULATION Based on state-of-the-art CAD software, we offer advice in terms of roll core dimensions and material selection. $ PIECE & SERIES PRODUCTION Your rolls can be produced on HEFNER s state-of-the-art roll covering systems and machined on CNC circular grinding machines. $ SPONGE RUBBER SPECIALIST The physical and chemical properties as well as the pore size of our sponge rolls are tailored to your requirements.

4 04 $ TASK HEFNER thoroughly evaluates specified customer requirements. The resulting roll specification forms the basis for the production process. $ DEVELOPMENT The quality of a roll is decisively determined by the grade and suitability of the compound used for this purpose. If your specific requirements cannot be met by one of our 500 standard compounds, we will tailor the recipe to your specific needs. $ SOLUTION Based on the roll specification, the individual manufacturing stages are defined and implemented in production. Consistent checks during the single production steps guarantee outstanding product quality.

5 05 IN-DEPTH ADVICE? A GOOD IDEA! Benefit from over fifty years of experience in rolls. We offer advice in terms of roll core rating and elastomer covering. IS PERFECT TOO AMBITIOUS A TARGET? For HEFNER it is the key to any new development. There are two key factors for the design of an optimum roll: the roll core and the elastomer covering. We advise you in the selection of the material, the design and the dimensioning of the roll core. Using state-of-the-at CAD software, we simulate and calculate the defl ection and load of the roll in your specifi c application. The covering quality is determined by the physical and chemical conditions the roll is used in. If none of our over 500 standard compounds complies with these requirements, we will develop an individual compound quality to your specifi cation. ROLL CORES STEEL, SPECIAL STEEL, ALUMINIUM,... Upon request, the rolls are surfacetreated, e.g. burnished, anodized

6 06 PRODUCTION: DEDICATION + COMMITMENT = MILESTONES HEFNER uses two state-of-the-art automated processes for roll covering to ensure optimum coating quality. THE ORIGIN OF INNOVATION IN ROLL DESIGN: the country of poets, thinkers and roll experts Our production department is equipped with two Large and individual rolls are manufactured fully automatic KraussMaffei Berstorff roll covering on a strip-winding system that allows a covering systems. thickness of up to 35 mm to be applied in a single working cycle. It is also possible to apply several Cutting-edge technology uncured layers, which are subsequently vulcanized Series rolls are covered on a Covermatic system. in an autoclave. Thanks to extrusion and inline With this line, we succeeded in drastically reducing straining, extremely homogeneous and pure coat- the manufacturing times in roll covering. The exact ings without any air inclusions are obtained with roll guidance and the automatic core feed give a pre- both processes. cise base size and a concentricity of about 1.0 mm.

7 07 $ RAW MATERIALS We purchase the raw materials for our compounds from renowned manufacturers and reliable suppliers to ensure consistent roll covering quality.

8 08 SPECIAL WISHES? THAT S HEFNER S SPECIALTY! $ TAILORED ROLL SOLUTIONS HEFNER rolls are tailored solutions for machine and original equipment manufacturers as well as for innovative users. Regardless of the complexity of our customer s wishes we manufacture exactly the roll you need. As a matter of course, your individual physical and chemical specifications are complied with. $ Roll coverings $ Piece and series production $ Profiles of all types $ Rubber coating renewal $ Complete rolls and component assemblies $ Short-term regrinding service $ Customised compound development

9 09 WE BRING YOUR ROLLS IN PERFECT SHAPE! Thanks to state-of-the-art CNC machinery, there are hardly any limits as to roll surface machining: diamond profiles, spiral-shaped or axial grooves, radial recesses, glue/lacquer profiles as well as special drive profiles. SINGLE PIECE OR SERIES PRODUCTION? Quality starts with the very first roll. Our quality management system is supported by the use of state-of-the-art CAQ software in series production. The fi elds test planning, test data acquisition, test equipment management, fi rst sampling, complaint handling and statistic evaluation are implemented in this application. During series roll production, the test data of the roll produced are recorded online and entered on a control chart. This allows the production process to be perfectly controlled and ensures the high quality standard of our roll coverings. The integrated management system as per DIN EN ISO 9001:2008 and 14001:2004 that was developed within the company is a guarantee for the quality of our products. Over fi fty years of experience gathered in the fi eld of technology provide a sound basis for high quality roll coverings. $ CNC MILLING This machining process provides maximum flexibility. The groove shape and the geometry are almost freely selectable. $ SURFACE QUALITY Depending on the coating material, surface finishes with a roughness of up to Rz2 can be achieved. $ SURFACE FINISHING High-tech CNC circular grinding machines ensure maximum precision in roll grinding. The CNC control guarantees exact reproducibility.

10 10 LARGE OR SMALL? SOFT OR HARD? THE CHOICE IS YOURS! $ ROLL DIMENSIONS $ Max. covering length: 6,000 mm $ Max. diameter: 1,000 mm $ Max. total weight: 2.5 tonnes $ COATINGS $ Solid Shore A $ Polyurethane Shore A $ Hard Shore D $ Sponge 5-25 Shore A $ Multi-layer covering (see figure on the right) $ Insulating, antistatic, conductive $ Non-slip to non-adhesive $ Resistant to chemicals, wear and high temperatures $ Suitable for food contact as per BfR and FDA 3-layer roll Solid / sponge / solid 2-layer roll Solid / solid or sponge / solid $ RUBBER BONDING on the following materials: $ Steel $ Special steel $ Aluminium $ CFK $ Plastics $ Hard cardboard 1-layer roll solid or sponge RANGE OF ELASTOMERS Styrene butadiene Acrylonitrile butadiene Ethylene propylene terpolymer (Synthetic) Natural Chloroprene Bromobutyl Chlorosulphonated urethane Poly - polyethylene Silicone Hydrogenated ayrylonitrile butadiene ISO code SBR NBR EPDM NR (IR) CR BIIR CSM AU / EU VMQ HNBR FKM x Mechanical properties Hardness range Shore A Max. permanent temperature C Compression set 72h / 23 C Compression set 24h / 70 C Elasticity Abrasion resistance x Resistance to Ozone UV light Fluoro terpolymer Water / hydrous solutions (23 C) Hot water / steam (up to 100 C) Oil / grease Aliphatic hydrocarbons Aromatic hydrocarbons Ester Ketone Alcohols / glycols Dilute acid Dilute brine Caption outstanding excellent above average average poor bad / unsuitable

11 OUR MODEL RANGE: A WIDE VARIETY OF SHAPES WITH THE MOST DIVERSE PROFILES. 11 ROLL GEOMETRY $ CYLINDRICAL e.g. standard rolls, printing rolls, winding rolls $ CROWNED (CONVEX, CONCAVE) e.g. for compensating the deflection line $ TRAPEZOIDAL CROWNING e.g. belt drive rolls for belt centring $ CONICAL e.g. rolls for curves in conveying equipment EDGE DESIGN $ RECTANGULAR $ STEPPED $ ROUNDED OFF $ CHAMFERED PROFILES $ DIAMOND PROFILE e.g. drive drums, vent rolls $ SPIRAL-SHAPED GROOVES e.g. abrasive belt grinding rolls $ SPIRAL-SHAPED GROOVES (STARTING IN THE CENTRE) e.g. dewatering rolls, spreader rolls $ AXIAL GROOVES e.g. feed rolls, belt drive rolls $ RADIAL RECESSES e.g. transfer rolls, format rolls $ GLUE/LACQUER PROFILE profiled rolls for applying a defined quantity of glue or lacquer $ SPECIAL PROFILE AXIAL GROOVES e.g. stalk separating rolls $ SPECIAL PROFILE e.g. grid belt drive rolls in conveying equipment

12 HEFNER GmbH & Co. KG Gummiwalzenfabrik Siemensstraße Gärtringen, Germany T +49 (0) F +49 (0) info@hefner.de WANT TO KNOW MORE? We will be pleased to provide you with more detailed information by phone or in a personal meeting. r T +49 (0) r consulting@hefner.de SUBJECT TO TECHNICAL CHANGES HEF_2011_004