1 Industrial Rubber Roll Amit Gupta Modinagar Rolls Limited March 5, 2014 AT ETDS.

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AN OVERVIEW OF THE ROLLER INDUSTRYAN OVERVIEW OF THE ROLLER INDUSTRY

Why are rollers used What is a roller Where are rollers used How are rollers manufactured Where is the roller market going

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Why Roll Coverings?Why Roll Coverings?

Virtually all industries use rollers of some type

Elastomer covered rolls provide performance factors not possible with rigid materials

Large number of polymer types and compounding ingredients allow tailoring of the roller to meet specific service requirements

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Rubber Covered Roll CompositionRubber Covered Roll Composition

Core Metal (Steel, Al, Bronze) Nonmetal (FRP)

Bonding layer Bonding agent

Cover Rubber, Polyurethane, Resin

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Polymers

Thermoset plastics Thermoplastic elastomers

Thermoplastics

Elastomers

• Phenolic or melamine resins

• epoxy and polyester resins (UP)

• etc.

• PP

• PE

• PS

• PVC

• etc.

• copolyesters

• polyether block amides

• TPU

• TPO/TPV

• SBS, SEBS

Natural rubber synthetic rubber

• SBR• NBR• EPDM• Silicone • etc.

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What is a Roll Cover?What is a Roll Cover?

Rollers are covered with elastomeric

compositions to allow the creation of a

uniform pressure area called the “NIP” “NIP” region dynamic performance must

remain constant Roller compounds must be stable over

time in the service environment

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Functions of Roller CoveringsFunctions of Roller Coverings

Feed Meter Emboss Insulate Conduct

Electricity

Drive Squeeze Stamp Isolate Dissipate

Electricity

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Roller Design FactorsRoller Design Factors

Solvents & ChemicalsTemperaturePressureRotational Speed

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Wide Range of ElastomersWide Range of Elastomers

NBR NBR/PVC XNBR HNBR EPDM CSM CR ECO

AU, EU NR SBR MQ MQ/EPDM FKM Thiokol

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Some Important Properties forSome Important Properties forRubber RollersRubber Rollers

Hardness Modulus Tear Strength Cut Resistance Compression Set Permanent Set Resilience Smooth surface

Abrasion resistance Hysteresis Chemical Resistance Ozone Resistance Heat Resistance Co-efficient of friction Non-glazing surface Good printability

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Rubber Roller DynamicsRubber Roller Dynamics - - The “NIP” areaThe “NIP” area

A

BC

D

E

HARD ROLL

ELASTOMERIC ROLL

A Entrance - compound relaxedB Entry Bulge - high extension & speedC Nip Center - high compressionD Exit Bulge - high extension & speedE Exit - compound recovered

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Roller Market SegmentationRoller Market Segmentation

4%

2%7%

9%

43%35% Graphic Arts

Pulp & Paper

Steel & Aluminum

Textiles

General Industrial

Business Machines

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Must be resistant to the

chemicals and Oils,,,

High elasticity with

abrasion resistance

Eccentrical property

during working

Changeable raw polymer

rely on changeable service

condition

Wringer rollers

Squeeze rollers

Coating rollers

Insulation rollers

Deflector rollers

Tension bridle rollers

Brake rollers

Support rollers

Steel mill Rubber RollersSteel mill Rubber Rollers

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Industrial Roller MarketsIndustrial Roller Markets

Paper industry Steel / metal

industry Furniture

Industry Wood Industry Plastic Industry

Food Industry Leather Industry Circuit Board

Industry

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Roller Manufacturing Processes Roller Manufacturing Processes SelectionSelection

Manufacturing process is selected based on:– Size of the roller

– Elastomer type

– Compound processibility characteristics

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Rubber covered rollRubber covered roll Recipe selection approach Recipe selection approach

Select a typical roll recipe and

various chemicals

List down the requirement of

properties

– Eg . least chemical affect.

Design experiments - “Ideal recipe”

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Various methods of covering rollsVarious methods of covering rolls

Casting - rollers used in Steel Mill, Pulp and Paper, and General Industrial.

Molding - small rollers used in Offset printing and Business Machines

Calender Building - medium rollers used in a majority of applications

Strip Building - rollers used in Graphic Arts, Pulp and Paper, Steel Mill, Textile and General Industrial

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Rubber Roll Manufacturing Rubber Roll Manufacturing

1. Mixing process

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Rubber Roll ManufacturingRubber Roll Manufacturing

2. Covering machine and roll

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Rubber Roll ManufacturingRubber Roll Manufacturing

3. Rubber covered roll-Autoclave for curing

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Rubber Roll ManufacturingRubber Roll Manufacturing

4. Rubber covering - Cured roll maturing

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Rubber Roll ManufacturingRubber Roll Manufacturing

5. Rough Grinding at Grinder

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Rubber Roll ManufacturingRubber Roll Manufacturing

6. Grinding

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Rubber Roll ManufacturingRubber Roll Manufacturing

7. Failure phenomenon - Hair crack

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Rubber Roll ManufacturingRubber Roll Manufacturing

8. Failure phenomenon - Destruction

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Industry TrendsIndustry Trends

Increasing environmental scrutiny New equipment designs Competitive pressure has led to

evaluation of alternative production technologies

Changes in industry will demand higher performance standards, and the roller industry must keep pace with these technical advances

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SummarySummary

Hardness Hardness stability Chemical and Solvent resistance Hysteresis loss Dimension stability Permanent set

resistance

Rollers are used in nearly every industry

Rollers utilize nearly all polymer types because of the diverse applications

Successful players in the roller industry will be those who are successful communicators and are able to meet the current & future requirements, and adapt to the industry changes