Qingdao Beishun Environmental Protection Technology Co.,Ltd
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Rubber calender is one of the most important heavy-duty and high-precision machinery in the processing of rubber and plastic products. It plays a key role in producing high-quality rubber products that meet industrial and consumer demands. A detailed overview of rubber calender is provided below.
Rubber calender is made of several components, such as working rollers, frames, machine bases, transmission devices, speed and distance adjustment devices, roller heating and cooling devices, lubrication systems, and emergency stop devices. Each component performs a crucial function in maintaining the efficiency and stability of the equipment.
The working roller is the core component of the rubber calender. It is made of high-quality alloy steel, extremely hard and durable, and has high strength to withstand the massive pressure and friction generated during the calendering process. The surface of the roller is finely processed and treated to ensure its surface finish and flatness, thereby ensuring the quality of the rubber products.
The frame is used to support and fix other components such as rollers, transmission devices, and pitch adjustment devices. It must have sufficient strength and stability to ensure that the calender will not shake or deform during operation. Meanwhile, the machine base plays the role of carrying the entire calender equipment and is usually made of heavy cast iron or steel structure, which can effectively disperse the weight of the equipment and ensure the smooth operation of the equipment.
The transmission device transmits power to the roller so that it rotates at the set speed. Its performance directly affects the working efficiency and stability of the calender. On the other hand, the speed adjustment device can adjust the speed of the roller according to different process requirements to meet the various process requirements of rubber calendering. Meanwhile, the distance adjustment device is used to adjust the distance between the rollers to control the thickness of the rubber product. Moreover, the roller heating and cooling device is used to heat or cool the roller during the rubber calendering process to ensure the plasticity of the rubber and the quality of the product.
The lubrication system provides lubrication for the various moving parts of the calender, reducing friction and wear while extending the service life of the equipment. It usually includes oil pumps, oil pipes, filters, lubrication points, and other components. Lastly, the emergency stop device is an essential safety feature that cuts off the power supply of the equipment when the calender encounters abnormal conditions during operation, such as roller jamming or transmission device failure.
During the rubber calendering process, the heated mixed rubber is squeezed and stretched through the gap between two or more rollers that rotate relatively and are horizontally set, thus forming semi-finished products such as films. In this process, the molecular structure of the rubber changes, its plasticity is improved, and the thickness, width, and other dimensions of the rubber are precisely controlled.
Rubber calenders can be classified according to their number of rollers and process use. The arrangement forms for each are also different. Each calender is designed to meet specific process and product requirements, and choosing a particular type of calendering machine could make all the difference in creating quality products.
Rubber calenders have various parameter indicators that measure their performance. These include roller linear speed, speed range, speed ratio, and other factors that describe their production capacity and advanced technological features. These parameters should be checked regularly to ensure the calender performs optimally.
Proper maintenance of the rubber calender is crucial to its longevity, efficiency, and safety. It's important to perform routine and regular maintenance, check the calendering process and adjust the device settings frequently, and develop a troubleshooting strategy to ensure that problems are resolved as soon as they arise.
The rubber calender is an important machine used in the production of various rubber products. It works through the relative rotation of multiple rollers, which applies pressure to stretch and thin rubber materials to achieve uniform thickness control. The calendering process can be done with two, three, four, or more rollers depending on the machine's configuration.
The rollers are a key component of the rubber calender and are usually made of high-quality steel to ensure the calendered products' quality. They are designed to have high hardness, strength, and good thermal conductivity, as well as high surface accuracy. The machine is equipped with a complete transmission system that can accurately control the roller speed, achieve different calendering speeds and speed ratios, and meet various production needs. Additionally, it has a reliable spacing device that can flexibly adjust the spacing between rollers to adapt to the calendering of rubber materials of different thicknesses.
The rubber calender can accurately control the thickness, width, and other dimensional parameters of rubber sheets or profiles, with thickness tolerance controlled within a small range, like about ±0.02mm. Most rubber calenders have roller heating or cooling functions. The temperature control system can keep the roller at a suitable working temperature between 50℃ and 150℃, conducive to the plasticization and molding of rubber.
The rubber calender has high production efficiency and can operate continuously. It can quickly calender a large amount of rubber raw materials into products of required specifications. The hourly output varies according to the machine model and process; small ones may be several tons per hour, while large industrial ones can reach up to tens of tons. It is widely used in the production of various rubber products, such as tires, conveyor belts, rubber sheets, seals, etc., as a raw material processing link.
Here are different models of calenders available. These are:
The rollers come in different diameters and working lengths, as shown below:
| Roller dia | Roller working length |
|---|---|
| 160 | 320 |
| 250 | 620 |
| 360 | 1120 |
| 450 | 1500 |
| 550 | 1830 |
| 610 | 1730 |
| 810 | 2430 |
The roll ratio and linear speed vary depending on the model. Here is a table with the specifications:
| Item | Roll ratio | Roll linear speed (r/min) |
|---|---|---|
| XY-2I()320 | 1:1 | 7.79 |
| XY-2I()620 | 1:1 | 14.8 |
| XY-2I()1120A | 1:1 | 3-20.2 |
| XY-2I()1500 | 1:1 | 2.5-24.8 |
| XY-2I()1830 | 1:1.08 | 2-18.7 |
| XY-2I()1730 | 1:1 | 4-36 |
| XY-2I()2430 | 1:1 | 2-20 |
Each model has a range for adjusting the nip and a minimum calendering product thickness. The calendering product width also varies depending on the model. Here are the specifications:
| Item | Adjusting nip range (mm) | Min. Calendering product thickness (mm) | Calendering product width (mm) | Motor power (kW) | Overall dimensions (LxWxH in mm) | Weight (t) |
|---|---|---|---|---|---|---|
| XY-2I()320 | 0-4.5 | 0.2 | 250 | 5.5 | 2200x530x1470 | ~1.2 |
| XY-2I()620 | 0-5.5 | 0.2 | 580 | 15 | 3100x770x1590 | ~3 |
| XY-2I()1120A | 0-10 | 0.2 | 920 | 37 | 5400x1542x1681 | ~14.5 |
| XY-2I()1500 | 0-10 | 0.2 | 1250 | 45 | 7113x1595x2446 | ~22 |
| XY-2I()1830 | 0-12 | 0.2 | 1600 | 75 | 7420x1760x2760 | ~24 |
| XY-2I()1730 | 0-15 | 0.2 | 1500 | 90 | 5987x1860x2988 | ~30 |
| XY-2I()2430 | 0.5-25 | 0.5 | 2150 | 160 | 8690x3139x4270 | ~62 |
The operation process of the rubber calender includes preparation before starting, start-up operation, calendering process operation, and shutdown operation.
Before starting, the following steps need to be taken:
Check the various components of the calender, including rollers, transmission systems, spacing devices, temperature control systems, etc. Ensure that the components are firmly connected and there is no looseness or damage. Also, check the surface of the roller for debris or damage, which needs to be cleaned and repaired in time.
Prepare the rubber raw materials to be calendered, ensure that their formula is accurate, and the mixing is uniform. Also, prepare auxiliary materials such as additives and fillers that may be used according to production needs, ensuring that their quality meets the requirements.
Set the roller speed, roller spacing, working temperature, and other parameters in the control system according to the specifications and process requirements of the rubber products to be produced. For example, set the roller spacing according to the thickness requirements of the sheet when producing rubber sheets. Also, accurately set the appropriate working temperature corresponding to different types of rubber.
The following steps need to be taken for start-up operation:
Turn on the transmission system of the calender to rotate the roller slowly. Observe whether the roller rotates smoothly and whether there is any abnormal sound or vibration. In case of any abnormality, stop the machine immediately to check and troubleshoot.
While the roller is rotating, start the temperature control system to preheat the roller. Gradually heat the roller to the appropriate processing temperature range based on the set working temperature, generally between 50℃ - 150℃, depending on the type of rubber and process. Continuously monitor the temperature changes during the preheating process to ensure that the temperature rise is uniform and stable.
During the calendering process, the following steps need to be taken:
When the roller reaches the set temperature and rotates smoothly, feed the prepared rubber raw materials slowly and evenly into the feed port between the rollers. The feeding speed should be moderate to avoid too fast causing rubber to accumulate on the roller and unable to calender normally or too slow to affect production efficiency.
Pay close attention to the molding of rubber products during the calendering process, such as whether the thickness and width meet the requirements. If the thickness does not meet the requirements, adjust the spacing between the rollers in time through the spacing device. To check and adjust the uniformity of feeding and other related factors, in case the width deviates. If local unevenness is found, adjust the speed ratio of the rollers and other parameters appropriately to improve it.
Continuously check the quality of the calendered rubber products, including whether the appearance is smooth and flat, whether there are bubbles or impurities, and whether the dimensional accuracy meets the standards. If there are quality problems, analyze the causes in time and take corresponding corrective measures, such as adjusting process parameters or cleaning equipment.
The following steps need to be taken for shutdown operation:
When the current production task is completed or production needs to be suspended, stop feeding the rollers. Let the remaining rubber between the rollers continue to be calendered until all the rollers are sent out.
Turn off the heating function of the temperature control system and turn on the cooling function as needed to allow the roller to gradually cool down to prevent damage to the roller due to long-term high temperature. Also, convenient for subsequent equipment maintenance and cleaning.
After the roller has cooled to a certain degree and the rubber has been fully delivered, stop the transmission system of the calender to stop the roller from rotating.
After the shutdown, clean the calender thoroughly, remove the rubber and other debris remaining on the roller surface, feed port, discharge port, and other parts of the equipment, and prepare for the next start-up.
The machine is CE, ISO, and SGS certified and has a minimum order quantity of 1 piece. The price range is between 10000usd-150000usd, and the delivery time is 45 days. The payment terms accepted are L/C and T/T, and the supply ability is 50 sets per year. The cooling system is optional, and the type of machine is a calender machine.
Roller width ranges from 500-2000mm, and heating method could be through steam, oil, or electric. The control system is PLC. Customization services are also available to cater to our clients' specific needs. We are committed to delivering top-quality products that meet our clients' expectations and needs.
The Rubber Calender Machine will be packaged in a sturdy wooden crate to ensure safe delivery. The machine will be secured with foam padding and straps to prevent any damage during transit. The crate will also be labeled with the product name and handling instructions.
Shipping:
Once the order is confirmed, the Rubber Calender Machine will be shipped within 10 business days. The shipping method will be determined based on the customer's location and preferences. The customer will be provided with a tracking number to monitor the delivery status.
Q: What is the brand name of the calender machine?
A: The brand name of the calender machine is Beishun.
Q: What are the different models of the calender machine available?
A: The different models of the calender machine available are 4-roller, 3-roller, and 4-roller.
Q: Where is the calender machine manufactured?
A: The calender machine is manufactured in QINGDAO, CHINA.
Q: What certifications does the calender machine have?
A: The calender machine is CE, ISO, and SGS certified.
Q: What is the minimum order quantity for the calender machine?
A: The minimum order quantity for the calender machine is 1 piece.
Q: What is the price range for the calender machine?
A: The price range for the calender machine is between 10000 USD and 150000 USD.
Q: What is the delivery time for the calender machine?
A: The delivery time for the calender machine is 45 days.
Q: What are the payment terms for the calender machine?
A: The payment terms for the calender machine are L/C and T/T.
Q: What is the supply ability of the calender machine?
A: The supply ability of the calender machine is 50 sets per year.
