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Precision and efficiency: roll covering by extrusion
Roll covering by extrusion is a versatile and precise process that provides a uniform and resistant covering on rolls. This technology offers numerous advantages, including high precision, adaptability and efficiency, and is used in many industries to improve the service life and performance of rolls.
Advantages of roll covering by extrusion
Roll covering by extrusion offers several advantages over other processes:
High accuracy: Extrusion provides precise control over coating thickness, ensuring a uniform application across the entire roll surface.
Diverse material options: Extrusion can be utilized to apply a variety of materials, each tailored to specific requirements such as high abrasion resistance, chemical durability, or temperature tolerance.
Continuous process: : Extrusion is a continuous process ideal for high production volumes, significantly enhancing efficiency.
Adaptability: The process can be easily adapted to various roller sizes and shapes, making it suitable for a wide range of applications.
Areas of application for the extruded roll covering
Extrusion-coated rolls are used in numerous industries, e.g.:
- Paper and printing industry (coating rolls; transport rolls)
- Textile industry (dyeing rolls; transport rolls)
- Metal and steel industry (levelling rolls; coating rolls)
- Plastics and film industry (transport rolls)
- Food industry (transport and printing rolls)
rubicon's technologies for covering small and large rolls
rubicon offers advanced extrusion solutions as a core element for roll covering. Thanks to our extensive experience in this field, a wide range of system configurations can be realised with a central control system:
Pin Barrel Extruder
Our roll covering lines can be equipped with cold-fed pin barrel extruders. These extruders feature a newly designed die, a special screw configuration, and optimized extrusion tools that ensure uniform material output and consistent web geometry. Even highly viscous mixtures can be processed smoothly, enhancing the coating quality.
Technical data pin barrel extruder
| Type | EEK 63.14 M | EEK 90.14 M | EEK 125.14 M | EEK 150.16 M |
| Screw diameter D (mm) | 63 | 90 | 125 | 150 |
| Screw length L (mm) | 14 | 14 | 14 | 16 |
| max. screw speed n (min-1) | 75 | 60 | 45 | 45 |
| max. motor power P (kW) | 37 | 64 | 108 | 178 |
| max. output m (kg/h) | 150-250 | 350-600 | 550-1200 | 950-1800 |
Vent extruder
These extruders eliminate air bubbles and volatiles matters from the rubber compound, resulting in a more uniform and higher quality rubber coating. This improves the bond between the rubber and the roll core and ensures consistent coating quality.
Technical data vent extruder
| Type | EEK 32.16 V | EEK 45.16 V | EEK 63.18 V | EEK 90.21 V | EEK 125.22 V |
| Screw diameter D (mm) | 32 | 45 | 63 | 90 | 125 |
| Screw length L (mm) | 16 | 16 | 18 | 21 | 22 |
| max. screw speed n (min-1) | 90 | 70 | 85 | 80 | 55 |
| max. motor power P (kW) | 4 | 11 | 37 | 89 | 122 |
| max. output m (kg/h) | 10-12 | 15-35 | 60-120 | 150-480 | 320-650 |
Matrix extruder / head combinations
| Extruder sizes | 63 mm | 90 mm | 125 mm | 150 mm |
| Crosshead |
| X | X |
|
| Wide slot die | X | X | X | X |
| Rotohead |
| X |
|
|
| Strainer head |
|
| X | X |
Examples system configuration
Version 1:
Crosshead - Rotohead as well as combinations thereof in combination with pin barrel or vacuum extruders for core diameters of 15 mm - 50 mm
Tube storage unit: Crosshead and rotohead variants can be combined with magazine and handling systems, which provide a buffer store to maintain a continuous extrusion process.
Carterpillar: in various belt lengths for feeding the crosshead and rotohead versions or combinations
Rail systems: Depending on the required precision, flat rails to LM guides can be used
Diameter measurement: Integration of laser and X-ray measuring systems
Printer solutions: Various processes - tailored to the respective application
Separation solutions: In the case of batch vulcanization, we offer a wide range of solutions for separating blanks
Handling solutions: for the connection of further processes
Feeding systems: Feeding systems tailored for various materials and production needs. Facilitate the automation of the extruder feeding process.
Version 2:
Covering elements for roll diameters > 200 mm <= 2500 mm
Slot die: For the extrusion of rubber strips with possible strip geometries from 40 mm x 1.0 mm up to 120 mm x 15 mm. Further dimensions can be analyzed.
Production platform: The production platform transports all system components and is powered by a geared motor. Special guide wheels and a flat rail system ensure a uniform coating speed, resulting in a consistent coating of the roll.
Ribbon winder: Guides and applies the extruded rubber strip to the roll to be covered without deformation. A wide variety of covering variants such as flat and angled covering are possible. Settings such as angle, speed, contact pressure and layer thickness are automatically calculated and adjusted, or can be managed and called up via recipes.
Wrapping unit: Controlled application of the required wrapping after the covering process. Compatible with all standard wrapping materials, supporting a maximum roll diameter of 400 mm and a width of up to 150 mm.
Take-off roller unit: Aufnahme und Drehung des zu beschichtenden Bauteils. Die schlanke Bauweise gewährleistet minimalen Platzbedarf. Rollenabmessungen und -gewichte auf die spezifischen Kundenanforderungen zugeschnitten.
Pick-up and rotation of the component to be covered. The slim design minimizes space requirements. Roll dimensions and weights are customized to meet specific customer requirements.
rubicon's technology for roll covering at a glance
Rubicon’s roll covering systems are specially designed to coat all types of rolls, tubes, and cylinders used in industries such as paper, printing, plastics, textiles, steel, cable, and offshore. They can handle convex or conical parts with diameters ranging from 30 to 2,500 mm, applying coatings from 1 to 90 mm in a single operation.
Rubicon’s roll covering system features a comprehensive electrical control system with an industrial PC and touch panel, enabling safe, simple, and nearly fully automatic control of individual components. The system includes integrated recipe management, recording and storage of all process parameters, and a networked maintenance and online support system.
Roll covering tailored to your specific production needs
At Rubicon, we develop customized solutions in close collaboration with our customers. Are you dealing with roll covering and need support from a competent partner? We’re here to help: Just fill out and submit the form!
