Rolls for the plastic and rubber industries

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1 Rolls for the plastic and rubber industries

2 Breitenbach. The roll company. Quality and precision for your production More than 130 years of experience in roll production have left their marks all over the world. Especially in the plastics and rubber industries, our customers benefit greatly from the know-how that we have acquired over decades. Precision, ruggedness and correct temperature behaviour of our rolls are benefits that you will greatly appreciate in production. Just what you need Whether calendering, pressing, smoothening, laminating or coating: In the plastics and rubber industries, production requirements have increased during recent years. Whenever plastics or rubber in continuous runs is produced or finished, rolls are critical for the quality of the end product. Maximum precision in terms of geometry, concentricity, surface quality and service life is what is demanded. Nowadays, no manufacturer can afford to use too much material or to produce excessive waste. With our sophisticated quality management system we ensure that your requirements are positively met at all times. Therefore many companies in the plastics and rubber industries work with rolls made by Breitenbach. They are used for a large range of products such as foil for TFT screens, tyres for formula 1 cars, leatherette or PVC flooring. Rolls for production and processing of PVC ABS Polyester PP PC PMMA rubber

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4 Engineering and consulting We work out solutions No matter what roll design you need by cooperating with us, you will find the optimum solution. Whether massive rolls, rolls with throughbore, double-shell rolls or rolls with peripheral bores, we will design the rolls in accordance to our customers demands. What s more, the journals will be fitted in a manner to suit the loads occurring during production, i.e., shrunk in, bolted on or integral. In order to achieve the optimum properties for the barrel and the journals, we use castings from our own foundry as well as all kinds of iron, non-ferrous metals and even carbon fibre reinforced plastic. The roll surface is of major importance for product quality in the plastics industry. Therefore we provide a large range of special surface finishes, from hard chrome and nickel plating, to thermally sprayed coatings, to rubber and plastic coatings. All these are steps in our advanced development process. Roll engineering, layout and design are defined on an individual basis. Each roll that has been calculated is checked for its mechanical and thermodynamic features using simulation software and thus the design is then optimized.

5 Specially designed heating and chill rolls enhance product quality and thereby the productivity of your plant. Advantages of our rolls include: Least possible temperature deviations across the working width (<_ 1 C) Minimal barrel deformation in the production process Reduced energy consumption along with optimum heating and cooling characteristics Low wastage along with optimized material utilization

6 Mixing rolls A perfect blend For the production of rubber and PVC foil, you need mixing rolls to homogeneously masticate the prepared material. The mass is heated and mixed and at the same time the homogeneity of the material is enhanced. For these applications, Breitenbach generally recommends massive cast rolls with peripheral bores, but also cored rolls may be suitable. For mixing rolls, we attach great value to perfect concentricity, which is a prerequisite for efficient utilization of both material and energy. Mixing rolls for the production of: rubber PVC sealants

7 common dimensions materials heating method coatings barrels mixing rolls with peripheral bores diameter mm barrel length mm chilled cast iron (single material) tri-pass not common cylindricity 5-10 µm concentricity 5-10 µm roughness 0,1-0,8 µm cylindrical or crowned cored mixing rolls diameter mm barrel length mm chilled cast iron (single material) cored not common cylindrical or crowned, also with corrugation for rubber refining

8 Calender rolls Pressure and heat Plastic foils or sheets, rubber and tissues with a highquality surface or with several layers are almost always produced using calendering equipment. The smoother and more precise the rolls, the more exact and better the result. Therefore Breitenbach is committed to the achievement of minimum tolerances. Even the slightest surface deviation would cause devastating results. Cracks, pores or any other processing blemishes must be positively avoided. For a perfect product quality, the rolls often have to be crowned. By means of a CNC controlled grinding process, we produce an adequate profile to match the later bending curve compensation. As part of a proven quality assurance system, Breitenbach checks after each step that the required precision has been achieved. When rolls are to be heated or cooled, we provide various designs for generating the required temperature including displacement systems, thermal conduction elements and peripheral bores. Tempering can be achieved with various media such as steam, water, thermal oil or even electrical heating. For peripheral bores in the roll barrel, we have developed a proprietary method which guarantees the homogeneous tempering of the rolls: This is an important feature when the processed material changes its properties in a narrow temperature range.

9 common dimensions materials heating method coatings barrels calender rolls with peripheral bores diameter mm barrel length mm chilled cast iron (single material) chilled cast iron (compound casting with spheroidal graphite cast iron or grey cast iron core) PROFIT 1000 (high chrome alloy special casting) heat-treated steel single-pass tri-pass multi-pass chrome cylindricity 2-5 µm concentricity 2-5 µm roughness <_ 0,01-0,08 µm cylindrical or crowned hot grinding for high geometric precision at service temperature (usually C); matt finishing or corrugation is possible forged calender rolls with peripheral bores diameter mm barrel length mm forged steel tri-pass multi-pass chrome see above cored calender rolls diameter mm chilled cast iron (single material) hollow chamber n/a cylindrical or crowned barrel length mm

10 Chill rolls and smoothening rolls Well cooled Chill rolls are used for rapid and focused cooling of plastics during the production of thin foil or multi-layer foil. We offer various cooling options which provide the optimum performance to suit your application. Due to the much higher speed at which they are operated compared with smoothening rolls, very precise balancing of the roll body is required. At Breitenbach, the various roll elements are balanced separately to achieve the optimum result. Our rolls are therefore free from visible external balancing weights. Perfect finish Thermoforming foils and sheets made from PP, PE, PS, PMMA, PC and PET call for smoothening rolls that provide absolutely smooth surfaces. To us, particular coatings, hardened or corrugated surfaces and other special requests are a matter of day-to-day routine. We advise you in selecting the suitable design and configuration because we know what it takes. Smoothening rolls can be manufactured either as welded double-shell rolls (sometimes with a reinforced internal body) or as forged steel rolls with peripheral bores. Over the last few decades, Breitenbach has gained an excellent reputation for extremely smooth hard chrome surfaces. In particular, mirror-finished surfaces are one of our specialties. To achieve this, rolls are electrolytically chromium coated and then ground and polished in several steps.

11 common dimensions materials heating method coatings barrels smoothening and chill rolls of double-shell design or with peripheral bores diameter mm barrel length 4000 mm hardened steel unhardened steel various thermal conduction options within the roll; tempering using water or oil as a heat carrier chrome nickel For special applications, the roll barrel may be provided with a matt or engraved finish. cylindricity 2-5 µm concentricity 2-5 µm roughness 0,005-0,02 µm

12 Service Our service as strong as our rolls We will support you with our roll service whenever you need it, involving roll repair and refurbishment of damaged rolls. Inspections and some small repairs can be performed by our experts on site. Roll service at a glance: Cylindrical grinding and finishing High precision roll grinding using CNC machines, including special profiles and contours up to a mirror-bright finish Hot grinding CNC hot grinding at the intended service temperature, up to 225 C using water heating or up to 300 C using oil heating Turning and milling Turning of cylindrical, crowned or any other profiles, milling of knife edges or corrugating of rolls Balancing Static balancing or dynamic balancing in 2 or 3 planes Refurbishment and repair Restoration of damaged or worn-out rolls to their original condition, regrinding, installation of new journals, chrome plating, production of new internal or external bodies for doubleshell rolls, converting of cored rolls or rolls with throughbore to rolls with a peripheral heating system (if technically possible) New coating Coating of existing rolls with hard chrome, nickel, copper, stainless steel, ceramics, hard material, rubber, polyurethane or thermally sprayed special alloys

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14 Technical information Forged steel Breitenbach is using forged heat-treated steel for calender and smoothening rolls which are subject to high loads. Moreover, highly strained shafts and journals are manufactured from this material. Thanks to induction hardening, the surface hardness of heat-treated steel can be selected, the max. value being 60 HRC. Heat-treatable steels used: 34 CrNiMo 6 (1.6582) 42 CrMo 4 (1.7225) 58 CrV 4 (1.8161) Chilled cast iron Our chilled cast iron of the Tuk type is produced by vertical casting and is particularly suitable for mixing and calender rolls. This material may be produced either alloyed or unalloyed. Therefore the hardness of the white outer working zone can be adjusted between 530 and 650 HV and usually has a thickness between 12 and 20 mm. Available chilled cast iron materials: Tuk 00 Tuk 20 Tuk 10 Tuk 25 Tuk 15 Tuk 30

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16 Each roll is unique Our rolls are designed and produced according to our customers requirements. They are made from steel or chilled cast iron from our own foundry and are specifically composed to suit your application and surface finish. This results in what has made us renowned since 1866: High-quality rolls, with a worldwide demand and with decades of service life. We serve the following industries: plastic and rubber paper converting coating non-wovens pharmacy and chemicals feed stuffs food (plain and semi-luxury) Moon Werbeagentur GmbH, Germany Title: BREYER GmbH Maschinenfabrik Walzenweg Siegen-Trupbach, Germany Postfach Siegen, Germany Phone: +49 (271) Fax: +49 (271) office@breitenbach.de