Description
Calendering is a mechanical process with multiple rolls passing compound material , such as silicone rubber,EVA , plastics including PVC, polymer ,vinyl, and even paper ,cloth , textiles. Through this continuous compresses and smooths process for these material, it finally produce uniform standalone material sheets with custom width and thickness, which can be adjustable for the rolls as per your specific requirement.
The four roll calender adopt the latest features for obtaining uniform coating and sheet thickness, better productivity and processing of rubber ,it is mainly used for calendaring thin rubber sheet of inner liner and airtight layer of the radial tire,coating of fabric, canvas ,PVC film ,textiles rubberized, steel cord fabric rubberizedand other woven material , calendaring thin rubber sheet of inner liner and airtight layer of the radial tire.
The 4 roller calender machine consist of base,rack, two rollers, motor,reducer, friction gear, distance regulator, thin oil lubrication device and other main parts/components.
The calendering roller is made of chilled cast iron with vanadium and titanium alloys,which is hard and anti-wear. It is separately driven by DC motors, which allow you to adjust the speed range seperately .
Basically ,the roller are either circumferentially drilled or centrally bored,which make temperature well proportioned on the roll surface on working. Thus ,throught this special design ,it is great to heat up or cool down and process your raw material sheet.
We can custom made calender machine in wide range of size ,from small laboratory calender machine sized 6”x18” to 26”x84” industrial production machines. They can be furnished with Two, Three, Four and Five Rolls in different profile and inner liner.
Our quality rubber calender machine are applied for many products ,like sheeting for lining, PVC films, fractioning of tire fabrics for Bicycle/motor cycle /Auto tires, hoses beltings, profiling, cushion gum, etc.
At Simptek , we specialize in the sales, maintenance, and consultancy related to calender machine for various industries including paper, textiles, PVC, film, and rubber. As China leading manufacturers for rubber processing machine, we offer a wide range of calender in different size, tailored to meet our customers’ needs.
Our expertise enables us to provide calender rolls with high-quality coatings customized to our customers’ specific requirements. Whether enhancing production efficiency, improving product quality, or extending equipment lifespan, we guarantee tailor-made solutions.
Main Feature
Four-rolls Structure: Usually consists of three rolls, which are the core of the machine.
Roll Surface Texture: The roll surface has a specific texture to change the surface characteristics of the material, which can be designed and tailored as per your specific needs .
Roller Diameter and Length: The diameter and length of each roller can be customized for specific applications. Usually the infeed rollers are smaller and the calendering and discharge rollers are larger. The diameter of the rollers determines the thickness of the rubber compound.
Roller Material: the rollers are made of high quality chilled alloy steel, whose hardness reach up to 70HRD,which allow the rolls can resist abrasion and corrosion.
Roller Gap Adjustment : The calendering machine can be designed as hydraulic system or manual adjustment, which enables the operator to precisely adjust the distance between the rollers, so that gain the ideal thickness of material .
How does a Calendering Process Work?
The calendering process is a finishing operation widely used in many industries , like rubber , paper, textiles, cloth , plastic ,PVC, EVA film etc . A calender machine adopt a series of hard pressure rollers by passing them under significant pressure , in order to form or smooth a sheet of material
Here is how the calendering process works:
Step 1. Material
Firstly ,the compound material to be process, such as rubber ,fabric, textile ,paper, nonwoven, composite ,PVC or plastic EVA film, is prepared and fed into the rolls calendering machine. Of course ,before the process of calendering , these material may need pre-treatment processes such as drying, softening.
Step 2. Roller Configuration
The calendering machine consists of two or more chilled steel rollers, whose hardness can reach up to 70 HRC. These rolls may be arranged in several configuration, either vertically or horizontally in L style ,I style or Z format.
Step 3. Passing Through Calender Rolls
The material to be calendered, go through these pressurized rollers , which can be heated or cooled, depending on the material and your desired outcome. When the material passes through the nip among the rolls ,which create high pressure compresses on the material, reducing its thickness and increasing its density.
Step 4. Controlling the Rolls
Its speed, temperature, and gap between the rollers can be adjustable to control the degree of calendering. Through these series of operation , it can precisely control for the properties of thickness ,smoothness ,gloss of final material.
Step 5. Cooling and Winding
After the material are passed through the rollers, the calendered material need to be cooled or cut into desirable sheets according to your specific needs .
We Offers Various Roller Calender Machine
I Type vertical
L Type
Z Type
Two Rolls Calender
Three Rolls Calender
Four Rolls Calender
Five Rolls Calender
I-Type
This style exsit in 2 roller ,3 rolls and 4 rolls calendering machine . Its upper and lower roller rotates anticlockwise among these series of hard pressure chilled rollers , so that obtain the desired thickness, width and surface or smooth a sheet of material such as paper, textiles, rubber, or plastics
L-Type
L style textile calender machine ,just as its name ,with its L-shaped roll arrangement and adjustable line forces in the top nip and rear nip ,which provide not only this specific soft handle effect, but also a multitude of other effects, including smoothness and density.
Z-Type
With the name of Z-style arrangement. In this type, each roller is perpendicular to another pair roller. You can face a lower level of heat in this type compared to the other two roller arrangements above.
The Usage of Calendering in Textile, Cloth , Non-woven
*Provides highly lustrous appearance on the fabric surface.
*Provides smooth, glossy and silky touch to the fabric.
*Increases fabric cover factor
*Compress fabric and reduce thickness
*Causes a closing to-gather of the threads by flattening them & thus tending to fill up the inter stiches between warp and weft.
*Reduce air permeability by changing its porosity
*Increase opacity of fabric
*Reduce yarn slippage
*Flattens slubs
*Consolidation of non-woven
Wide Application
*Rubber & Related Products :Applied to rubber and rubber related products,such as tires , conveyor belts , gaskets , rubber tubes, seals, rubber pads etc.
*Silicone Products : Silicone is often used in electronics, medical, food and other industries due to its good high temperature resistance and aging resistance.
*is also suitable for paper, film, nonwoven etc.
*Composite Materials : Used to produce the middle layer of composite materials, such as carbon fiber reinforced plastics (CFRP), etc., and calendering is used to ensure that the layers of materials are tightly combined.
*Plastics and Polymers: The calendering machine are also suitable for production of various plastic and polymer-based products, ideal for polyvinyl chloride (PVC), polyethylene, polypropylene, and other thermoplastic resins ,so that achieve desired surface finishes, thicknesses, and physical properties.
*Floor Tiles: The rolls calendering machine are widely used to manufacture rubber floor tiles, which are widely adapted for playgrounds, gymnasiums, or high-traffic areas. You can cut them to meet custom flooring needs.
*Rainwear:The commingled fabric and rubber polymer result in the formation of raincoats or jackets.
*Luminous Ceilings:The calendering machine are also widely used to form very thin rubber sheeting that you can use in your ceilings.
*Furniture Upholstery: Rubber webbing replaces jute webbing because of unmatchable strength, flexibility, and durability. You can use it on various furniture accessories to make them aesthetically pleasing.
Simptek Calender Machine Advantage
Customizability: The two-roller calender machine can be customize and tailored in different configuration as per your specific work requirements.
Controllability: By adjusting the pressure and clearance of the rollers, the thickness and texture of the rubber can be precisely controlled.
Efficiency: The calender can produce a large amount of material continuously, which greatly improves the production efficiency.
Versatility: The machine has a wide range of applications in material processing and is suitable for many types of materials, such as rubber, plastic, silicone, food and so on. This versatility makes it suitable for almost all production needs.
Environmentally Protection : the two Rolls Calender Machine can be equipped with a recycling system to minimize energy waste and reduce the impact on the environment.
Stability: the calendering machines are usually very robust, capable of continuous operation, stable performance and long service life, but requiring less maintenance
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