Perfect solutions for premium-quality products Rubber sheet production lines Engineering Value
3 Perfect interaction for uncompromising product quality KraussMaffei Berstorff offers customized calender lines for the production of flooring sheets, uncured conveyor belts, printed blankets, roofing sheets, semi-finished tire components and fiber-reinforced rubber sheets as semi-finished products for rawedge V-belts. Calender lines for the production of different types of sheet feature the following benefits: Unparalleled output rate KraussMaffei Berstorff calender lines are designed for the production of sheets with a thickness of up to 18 mm at a maximum width of 3,200 mm. When combined with a laminating system, sheets of up to 30 mm thickness can be produced. High degree of automation The high degree of automation of our calender lines substantially reduces start-up time and scrap, retooling times and labor costs. Precise lamination The laminating system enables precise and uniform bonding of up to seven sheet layers in a single working cycle.
4 Rubber sheets 4-roll slash calender for the production of fabric or steel cord sheets coated on one or both sides Ideal for the following production processes: Calendering of rubber sheets of 0.1 4.0 mm thickness downstream from the calender Production of cover and adhesive sheets used for conveyor belts Production of rubber-covered fabric layers for technical rubber products used for printing blankets, consumer goods etc. Coating and frictioning of textile and steel cord inserts for the conveyor belt and tire industries Lamination of various rubber sheets Working width 800 3,000 mm (trimmed) Line speed 0.5 80 m/min 4-roll calender with slide block Roll diameter 450 850 mm Roll width 1,000 3,600 mm Adjustable roll rolls 1 + 3 + 4 Roll gap adjustment repeatability 0.002 mm Max. adjustment speed 22 mm/sec Parallel gap adjustment with user selectable precision of 0.001 mm Cross-axis adjustment to compensate the roll deflection for rolls 1 and 4 by means of hydraulic cylinders, up to max. 25 mm on each side Roll surface temperature user selectable control range from 40 to 130 C Thickness gauge customer-specific design Downstream equipment The downstream equipment comes in various customized variants, e.g.: Unwinder (4 unwinders for diameters of up to 2,000 mm) Material bobbin weight 25,000 kg, pull-roll stand and automatic center control Laminating unit with pneumatic rubber-coated contact roll Automatic center control for sheet centering Edge trimming unit Longitudinal cutters for center cut Motor-driven traversing or stationary cross-cutter Lateral travel winding systems with automatic center control for diameters of up to 4,000 mm
5 Multi-layer conveyor belts with fabric or steel inserts Line for discontinuous production processes Line for continuous production processes Project-specific convex roll grinding Bending and preloading device Edge trimming unit Material guide jaws Hydraulic contact rolls
6 Rubber sheets Roller-head lines for the production of rubber sheets (with optional profiling) Ideal for the following production processes: Calendering of rubber sheets Production of rubber sheets for technical rubber products Lamination of various rubber sheets Working width Line speed of 0.1 18 mm thickness of bubblefree sheets 500 3,200 mm (trimmed) 1 25 m/min Extruder for roller-head calender feeding Cold-feed pin-barrel extruders GE 120, 150, 200, 250 and 300 KS PinConvert extruders of size 120 300 Degassing extruders of size 120 300 Extruders with screen changer, size 120 300 Roller-head-calender (two rolls) Roll diameter 300 800 mm Roll width 700 3,620 mm Adjustable roll roll 2 (bottom roll) Roll gap adjustment repeatability 0.001 mm Max. adjustment speed 22 mm/sec Parallel roll gap adjustment in steps of 0.01 mm (user selectable) Cross-axis adjustment to compensate the roll deflection for rolls 1 and 2 by means of hydraulic cylinders, up to max. 25 mm on each side Roll surface temperature 40 130 C Downstream equipment Unwinder for 4,000 mm diameter Material bobbin weight 25,000 kg, pull-roll stand and automatic center control Laminating unit with pneumatic rubber-coated contact roll Edge trimming unit Longitudinal cutter for center cut (optional) Motor-driven traversing or stationary cross-cutter Lateral travel winding systems with automatic center control for diameters of up to 4,000 mm
7 Optional laminating unit Laminating of single layers to form a carcass
8 Rubber sheets Roller-head lines for the production of multi-layer sheets made of rubber, textile and fabric layers Production stages Frictioning / coating of single fabric layers Production of cover and adhesive sheets used for conveyor belts Production of rubber-covered fabric layers for technical rubber products like printing blankets, seals, etc. Calendering of rubber sheets Lamination of various rubber sheets Sheet thickness Line speed 0.4 18 mm 1.75 35 m/min Extruder for roller-head calender feeding Cold-feed pin-barrel extruders GE 120, 150, 200, 250 and 300 KS PinConvert extruders of size 120 300 Degassing extruders of size 120 300 Extruders with screen changer, size 120 300 Roller-head calender with slide block (3 rolls) Roll diameter 300 800 mm Roll width 700 3,620 mm Adjustable roll rolls 1 and 3 Roll gap adjustment repeatability 0.002 mm Max. adjustment speed 22 mm/sec Parallel roll gap adjustment in steps of 0.01 mm (user selectable) Fixed roll roll 2 Cross-axis adjustment to compensate the roll deflection Roll surface temperature 40 120 C for rolls 1, 2 and 3 by means of hydraulic cylinders, up to max. 25 mm on each side Downstream equipment Unwinder for diameters of up to 2,000 mm Hydraulic rubber-coated contact roll on the upper calender roll for additional lamination Automatic center control Edge trimming unit Longitudinal cutters for center cut Motor-driven traversing or stationary cross-cutter Lateral travel winding systems with automatic center control
9 Discontinuous production of rubber-coated fabric layers according to the roller-head principle Continuous production of rubber-coated fabric layers according to the roller-head principle (shown with accumulator)
10 Rubber sheets AUMA system for continuous vulcanization and lamination of rubber and plastic sheets Material feeding: calendered single- or multi-layer rubber sheets Output depending on formulation and material thickness Working width 600 3,200 mm 1,650 mm 1,400 mm 19,500 mm Heating drum dia. 600 5,000 mm Theoretical heating length 1,280 7,000 mm Adjustable heating time 1.2 24 min Production speed 0.25 5.0 m/min Specific surface pressure in heating zone 60 N/cm 2 Heating of the heating drum steam of up to 20 bar, HTM up to 210 C Surface temperature 150 C 190 C, as required Temperature distribution on the heating drum surface over the working width +/ 1 C Machine sizes and technical specifications Type Drive (kw) Output at heating time 1 30 min (m/h) Output at heating time 0.4 12 min (m/h) 6 3 78.6 2.6 192 6.4 20 15 33 25 Average steam consumption (D) in kg/h and installed radiation heating power * (R) in kw for working widths (mm) 600 1,000 1,250 1,500 1,600 2,000 2,500 R D R D R D R D R D R D R D 10 5.5 147 4.9 367 12.3 40 50 60 65 80 12 S 7.5 140 4.6 54 50 68 60 82 75 15 SN 7.5 210 7 525 17.5 (70) 60 (90) 75 (105) 90 (110) 95 (140) 120 15 S 7.5 210 7 525 17.5 70 60 90 75 105 90 110 95 140 120 20 S 15 270 9 675 22.5 80 80 100 100 120 115 130 125 165 150 200 190 25 S 15 348 11.6 870 29 130 215 160 260 170 270 210 320 260 380 30 S 22 420 14 1,050 35 160 270 190 300 200 320 250 380 310 460 * Consumption = approx. 50%
11 AUMA IM 6 and IM10 The latest version for laboratory and production-scale applications. AUMA 6 50 for production applications
12 Rubber sheets Application examples of roller-head lines for the production of printing blankets Ideal for the following production processes Frictioning of rubber sheets Coating of rubber sheets Working width Sheet thickness 800 2,850 mm (trimmed) 0.5 2.0 mm Extruder for roller-head calender feeding Cold-feed pinconvert extruder 150 SC or 200 SC Cold-feed and warm-feed extruders Output rate: max. 2,500 kg/h depending on viscosity, max. admissible stock temperature and discharge cross-section Roller-head calender (3 rolls) Roll diameter 600 750 mm Roll width 1,000 3,500 mm Adjustable roll 1 and 3 Roll gap adjustment repeatability 0.002 mm Adjusting speed max. 22 mm/sec Parallel roll gap adjustment in steps of 0.01 mm (user selectable) Fixed roll roll 2 Cross-axis adjustment to compensate for rolls 1, 2 and 3 by means of hydraulic cylinders the roll deflection Roll surface temperature 40 120 C Thickness gauge contactless air cushion measuring system, accuracy +/ 0.010 mm, depending on thickness Downstream equipment Thickness gauge Hydraulic rubber-coated contact roll on the upper calender roll for additional lamination Automatic center control for perfect fabric alignment upstream from the inlet into the take-off unit Edge trimming unit Lateral travel winding systems with automatic center control Material Fabric sheets: any fabrics up to 220 g/m 2 (full fabric), approx. 0.25 3 mm thickness, optionally four layers Rubber: coating with a calendered rubber sheet, 0.09 1 mm thickness Required dimensional accuracy of the product Rubber sheet for coating the semi-finished product parallelism ± 0.03 mm Product quality characteristics Homogeneous rubber sheet with smooth unprofiled surface finish Crease-free
13 Frictioning Coating Frictioning and coating
14 Rubber sheets Extrusion technology Extrusion technology Premium quality and unparalleled productivity For state-of-the-art extrusion concepts, the following essential requirements are a must: High degree of innovation to ensure competitive production in terms of quality and cost-effectiveness. Tailor-made design to meet specific requirements of different compounds and production processes. Uncompromising time-tested reliability to ensure unparalleled efficiency and productivity. KraussMaffei Berstorff has accepted this challenge and developed different extrusion processes designed to achieve premium-quality products and maximum output rates. KraussMaffei Berstorff s GE-SC pinconvert and GE-KS pin barrel extruders for rubber sheet production set new benchmarks in extrusion technology. They combine all benefits of state-of-theart machine technology like outstanding reliability, unparalleled durability and uncompromising ease of maintenance with maximized output rates. Technically mature systems for premium quality The processing section of KraussMaffei Berstorff GE-KS pin barrel extruders is equipped with pins that are distributed symmetrically over the circumference and reach almost up to the screw core. In addition, the screw flights of the screws used for this purpose are interrupted in the area of the pin planes. The pins are designed first of all to increase the friction coefficient between the barrel wall and the cold compound. This changes the ratio between the axial and radial flows in favor of the axial flow and the conveying capacity of the screw is enhanced. As soon as the compound has heated up about half way through the processing section the pins continuously rearrange the material and divide it into several partial streams that flow together again at relatively low shear speeds. The number of pin planes and the number of pins per plane depend on the material to be processed and the specific application. Adjusting ring with vacuum unit of a pinconvert extruder Screw type Temperature Quality Output A ++ B + / + + / C + + / + C+ + + + D + ++
15 Roller-head dies 3,300 mm timmed width Roller-head dies for the production of rubber sheets with a width of up to 3,300 mm provide premium product quality, high throughput rates and unparalleled reliability combined with minimized maintenance requirements and short set-up times. KraussMaffei Berstorff extrusion dies are connected to the processing section by means of flanges, clamp connections or bayonet locks. Manual or hydraulic connections facilitate cleaning operations and allow the die to be rapidly replaced. High-performance GE pin barrel extruder with slot die Slot die with optimized flow channel geometry
16 Rubber sheets Powerful calendering solutions for sustainable process optimization The rubber sheet production process is characterized by closely linked process stages. With its calendering technology portfolio comprising calenders of I or inverted L design with 2, 3 or 4 rolls and 5-roll calenders, KraussMaffei Berstorff offers an extensive range of different solutions. The modular set-up and various accessories provide maximum flexibility and outstanding productivity. Design features of KraussMaffei Berstorff calenders at a glance: Rolls made from premium quality materials with high concentricity and dimensional accuracy, unparalleled surface quality and hardness Various calender heating options Excellent concentricity owing to special roll bearings with oil circulation lubrication Hydraulic roll gap adjustment gives short response time at maximum adjustment precision, uncompromising repeat accuracy and rapid roll gap opening Hydraulic cross axis adjustment and roll bending device to compensate roll deflection Calender drives of sustained premium quality for the most varied applications Material savings owing to close machine tolerances State-of-the-art calender 1 mm layer of ± 60 µm Rubber sheet with 1000 µm thickness Tolerances 60 +60 New slash calender 1 mm layer of ± 20 µm Rubber sheet with 1000 µm thickness Material savings 4% less material owing to close concentricity tolerances 40 µm 0 200 400 600 800 1000 1200 Material savings New slash calender 1 mm layer of ± 20 µm State-of-the-art calender 1 mm layer of ± 60 µm Rubber sheet thickness 1020 1000 1000 Minus tolerance 40 20 60 Plus tolerance 20 60
17 Convincing designs for the most varied products highly flexible and reliable solutions KraussMaffei Berstorff offers an extensive portfolio of upstream and downstream auxiliary equipment customized to your individual requirements. This equipment includes different types of winders, contactless thickness gauges as well as laminating and cutting systems that are perfectly tailored to the specific process and ensure short retooling times and maximum reliability. Sturdy construction for premium quality KraussMaffei Berstorff two-roll calender The requirements on calender lines are becoming increasingly complex highest cost-effectiveness, unparalleled equipment reliability and outstanding product quality. As maximum customer benefit is one of our main objectives, we at KraussMaffei Berstorff focus on providing professional customer advice right from the beginning. 1,300,000 1,200,000 1,100,000 1,000,000 900,000 800,000 700,000 600,000 500,000 400,000 300,000 200,000 Savings based on 4% less material Material savings [kg/year] Figures based on: Rubber compound price: EUR 3.00 Production per year: 7200 h Material savings [EUR] 4,500,000 4,250,000 4,000,000 3,750,000 3,500,000 3,250,000 3,000,000 2,750,000 2,500,000 2,250,000 2,000,000 1,750,000 1,500,000 1,250,000 1,000,000 750,000 0 1000 2000 3000 4000 5000 6000 Capacity [kg/h]
18 Rubber sheets Additional information OEE Plus Boosting your cost efficiency High overall equipment efficiency (OEE) is a fundamental prerequisite for your company s success. This is why KraussMaffei Berstorff s product portfolio comprises tailored machines and lines along with perfectly matched services that increase the economic efficiency and sustainability of your production. Benefit from our profound process know-how and long-standing experience in extrusion for a wide range of different applications. Availability Performance For more information about OEE Plus, visit: www.kraussmaffeiberstorff.com/oeeplus Quality
19 KraussMaffei Berstorff A strong brand in a unique global group Value-proven extrusion technology solutions Around the world, KraussMaffei Berstorff stands for reliable and value-proven solutions in extrusion technology. These include individual extruders and complete extrusion lines for degassing in polymerization, compounding, pipe, profile, film and sheet extrusion, physical foaming and the manufacture of technical rubber products and semifinished tire components. All machines and systems from KraussMaffei Berstorff are custom-configured, for example for the chemical, automotive, construction, packaging or pharmaceutical industries. There for you around the world KraussMaffei Berstorff is your partner from the first planning meeting, the development of the ideal technical and cost-effective solution right through to commissioning, production and servicing of your line. We guarantee high-quality advice, solution expertise, reliable spare parts logistics and short service response times in all phases. We are strongly committed to increasing your success. Individualized service Benefit from KraussMaffei Berstorff s reliable service. Our customer service team and experienced fitters, technicians and engineers are there for you as quickly as possible and even provide onsite help to optimize your systems and processes and to minimize downtime. Rely on our highly skilled repair and spare parts service. KraussMaffei Group Comprehensive expertise Technology3 the unique selling point The KraussMaffei Berstorff Group with is three distinct brands KraussMaffei, KraussMaffei Berstorff and Netstal is the only provider worldwide to unite under one roof the entire range of machine technologies for plastics and rubber processing, injection molding, automation, reaction processes and extrusion applications. The group is represented at international level by more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our comprehensive and unique expertise in this branch of industry. For further details about KraussMaffei, please visit: www.kraussmaffeigroup.com The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in light blue.
Perfect solutions for premium quality-products Rubber sheet production lines Benefits of KraussMaffei Berstorff sheet production lines: High degree of automation The high degree of automation of our calender lines substantially reduces start-up scrap, retooling times and labor costs. Constant performance The innovative machines and lines delivered by KraussMaffei Berstorff are successfully operated at maximum performance in hundreds of companies 24 hours a day, and 7 days a week! www.kraussmaffeiberstorff.com 1.0 GB. 1st edition, 10/16 EXT 020 A PRO 11/2016 EN Subject to technical changes. Printed in the Federal Republic of Germany