What are the ways to clean Rubber Rollers? How to prolong the durability of Rubber Roller?
Over the years technology has been at the driver’s seat in a wide gamut of industries, including industrial Rubber Rollers. Technology-driven companies are way ahead of their competitors, adapting modern technologies they reap substantial benefits from the technology executed. The Rubber Roller manufacturing companies aren’t lagging behind. In fact, many of them are harnessing the technology to scale up their production cycle and manage myriad processes seamlessly. Before shifting gears to the pivotal subject, let’s strive to comprehend the Rubber Roller in short! Understanding the Rubber Roller Industrial Rubber Rollers are being capitalized for different functions in manufacturing processes, including embossing machines, graphic art, laminating machines, offset printing, spreader, and laminator among others. Moving on to the manufacturing industries leveraging the roller, these include paper industry, plastic industry, textile mills, tyre, and lamination among others. The industrial Rubber Roller is a sophisticated product crafted with precision using modern tools and technology. In layman’s language, it’s an elastic material covering the core which is made up of metal or any other material. Why clean the Rubber Roller? Regular maintenance and cleaning of the product optimize durability. Being a businessman you are familiar with the significance of durability for a company. Increased durability directly impacts the growth of the company. A substantial amount of money could be saved merely through proper maintenance of the product. Well, look no further, let’s now move on to the pivotal subject – how to prolong the durability of Rubber Roller? Optimizing the durability of Rubber Rollers Cleaning and wiping: Instill this habit among the workforce, clean and wipe the roller at the end of the day on regular basis. This simple yet powerful habit would facilitate in eliminating unwarranted dust and dirt. Several industrial roller companies in India have integrated this process at their manufacturing facility. Before cleaning the roller, make sure you hold basic knowledge of the rubber compound, surface, and hardness. Otherwise, what will happen, certain chemicals might wreak havoc on the rubber surface. Your vendor can help you out with impeccable information. High temperature is dangerous High temperature and rubber are arch-rivals. Exposure of the product to high temperature damages its durability. Heating also impacts durability as bonding adhesive is vulnerable to high temperature and heat. Storing Every roller has a designated model to store it properly. Deviation from the standard process could severely damage the life span of the product. You don’t have to go overboard to prolong the life of the roller. So, how to store the roller? Many Manufacturers in India offer leaflets with clear instructions on storage. Hold the shaft and stand the roller upright, reason is – protect the rubber from coming in contact with damaging external material. Avoid UV radiation Exposure to UV radiation is harmful to rubber rollers. That’s why you are instructed to store your company’s valuable business asset in a dark place. Maintenance check Be meticulous during maintenance check of rubber rollers. Means? While inspecting a rubber roller, note down worn-out and damaged parts, like bearings, faulty gears, imbalanced rollers, etc. In case worn-out parts are remediable, get these repaired without a wait. Else, you can replace faulty parts with new ones. Maintenance isn’t rocket science; however, a comprehensive and structural policy is required at the workplace to imbibe the practice among the workers engaged in the operation. Besides, you can also roll out a regular inspection policy with crystal clear accountability. No point in executing a policy, if it’s not being adhered to in letter and spirit. Summary Industrial Rubber Rollers as suggested require regular maintenance and upkeep. It’s in the interest of the industry too? Why? Adherence to maintenance leads to optimal performance and durability.
Describe how industrial rubber rollers are manufactured
Over the years, rubber rollers manufacturing process technology has evolved substantially. Manufacturing companies across the globe, including India, are adapting new tools and technology to fabricate business-centric range enabling companies to materialize their business objectives. Redundant technology and processes are in fact swiftly fading away from the market. Rightly so! Obsolete methods increases production cost. In this short blog, we are going to highlight the manufacturing process, how industrial rollers are manufactured using modern tools and technology. Manufacturing process Industry experts have defined the manufacturing process in five stages: Preparation of Core and Rubber to Metal bonding A flawless adhesion between rubber and core is important as it plays a significant role in optimizing performance of rubber rolls in different industries. The process begins by exposing the cores to steam at about 150°C for numerous hours. This keeps anticorrosive materials applied on new cores at bay. When such similar processes are over, the cores are exposed to sandblast. It produces a unique metal surface, absolutely free from rust and dust. Using solvent, the cores are washed to ensure that it’s free from any grease or oil trace. In the form of a thin film, chemical bonding agents are applied evenly using a brush. The moment the film of bonding agent has dried, commence the buildup of the roll. Formation of Rubber Covering The first step is followed by the formation of a rubber covering. The rubber cover compound measuring 1.0-1.5 mm thick goes through cooling process with the support of cooling drums. Later on it’s wound with a polyethylene sheet. Now it’s time to apply a cover sheet over the core with the help of hand rollers. In many situations, use of extruded sheeting is preferred over calendered sheeting. There are reasons supporting it. Because the sheet doesn’t reflect any kind of blisters. These blister-free sheets can be of higher thickness (range of 4-8 mm). Such a feature reduces building time. Besides, there are a few other methods for the formation of rubber covering. Vulcanization Under the vulcanization process, crosslinks are created between the elastomer chains or the rubber compound. This process lends the polymer its necessary physical properties. The process of vulcanization is carried out by introducing the heat into the system. This supports the bonding of the curative agents, including sulfur and peroxide. Post heating process, the rubber is left to cure for a few hours. Later on, the rubber roller is cooled for the subsequent stage. Groove Cutting Under this process, specially designed grooved regions are created on the surface of the rubber roll. Subsequently, the surface area is expanded. The expanded area prevents slippage and improves heat dissipation. In addition, it is used for embossing and print patterns. Grinding Grinding process enables in smoothening the surface of the rubber cover as it wards off protruding parts. Besides, there also levels overlapping strips. The grinding process is carried out through a sophisticated machine called a grinding machine. The rubber rollers are rolled through an abrasive wheel, a kind of a turning lathe. Balancing is the last stage of the industrial roller company manufacturing rubber roller. There are two ways by which a roller can become imbalanced: static and dynamic. According to industry experts, static imbalance is identified when the roller rolls to its heavy side whenever allowed to rotate freely. Whereas a dynamic imbalance occurs when a rubber roll is rotated to its operating speed and generates vibration. Through testing the roller into a computer-monitored dynamic balancing system, dynamic balancing is addressed. Summary Taking into account various challenges and problems being faced by numerous industries, including packaging, textile, paper, plywood and laminate among others, the product is manufactured using innovative technology and processes.