What is a Rubber Roller?

A rubber roller is a round shaft usually made of steel, aluminum, carbon fiber or any other composite material. it is covered with an elastic layer known as rubber. A roller is known to be used in many industries like printing and packaging, paper making and converting, Lamination coating and many other industrial applications.

Characteristics of a Rubber Roller

• High coefficient of friction
• Quickly returns to its original shape when the shape is distorted.
• Resistant to chemical substances and protects the roller core and shaft.
• Prevents damage caused by scratching and bumping. 
• Compensates for small changes in machine precision
  
  

It has many uses:

• as a dielectric or insulator
• as a conductor and semi-conductor on changing the electrical properties
• as a high-release material (Silicon rubber)
• with special surfaces (plate roller, grooved roller, helical processing, etc.)
• Others

Manufacturing of rubber rollers, maintaining such characteristics above, requires sophisticated technology and experience. We focus on;

• The performance of the rubber compound
  The performance of the rubber much depends on the formulation of rubber chemicals even though the base polymer is the same.
  
  
• Finishing Precision
  Finishing is a crucial operation that define the working condition of the rubber roller used in its inteded application.
  
  
• Stable Quality
  Stable strength, uniform hardness, minimal foreign particles, pin holes etc..
  
  
• Roller core material and structure
  Stable strength, uniform hardness, minimal foreign particles, pin holes etc..
  
  
• Proper bonding of rubber and core
  Rubber is tightly bonded to the substrate, weak bonding may result of rubber being peeled off the steel core or breaking.

Roller Core Materials

Roller Balancing

The high speed and reliability requirements of machines used to print, recycle, manufacture and process paper pulp and associated products require that the components in each machine be balanced to prevent vibration, heat build-up and bearing failure, and also decrease noise. Additionally, cooling fans, print rollers and rolling guides, drive shafts, and impellers used in such machines all work better and smoother when balanced - especially when such components are operated at high speeds.

TRAD ROLLERS employs the following methods to adjust the unbalance:

1- Static Balancing
The Roller balance is checked by seeing if the roller moves on the sharp edges as shown in the sketch. Correction is made by adding weight to the lighter side or lightening the heavier side.
2- Dynamic Balancing
The unbalanced weight is described as centrifugal force which results in the roller swinging in a certain direction. To correct the dynamic balance, the roller surface is divided into 360 equal parts and weight adjustments are made at the positions where the unbalance is exerted.

Crown Processing

 The purposes of rollers crowning are:

• Correction of deflection during service
• Making an appropriate flow of the substrate

 Crown Types

Special Surface Grooving

Name	Groove Pattern	Application
Vertical Groove		Emboss on plastics Assist the heat release from rubber rollers. Apply softness of rubber rollers. Raise the coefficient of friction.
Horizontal Groove		Emboss on plastics Prevent a belt slipping and meandering Apply softness of rubber rollers. Raise the coefficient of friction.
Helical Groove		prevent a belt slipping and meandering assist the heat release from rubber rollers.
Double Helical Groove		Prevent a belt slipping and meandering Assist the heat release from rubber rollers. Smooth out wrinkles in plastic films and papers.
Diamond Cut Groove		Prevent a belt slipping and meandering Assist the heat release from rubber rollers. Improve contact stability with papers or plastic films.
Screw thread Groove		increase the amount of coating

Custom Grooving Patters are also accepted.
Ps. Customers are adviced to provide the following information depending
on the type of grooving needed: 

• Number of Grooves Needed.
• Angle of the Spiral
• Grooves Depth

Transport Instructions

In order to ensure delivery of parts in acceptable condition, compliance with the following points is absolutely essential:

• Using A sturdy wooden box is recommended.
• Due to the increased risk of injury, cartons must be closed not with metal staples but with adhesive tape.
• Attach a rope to the shafts or attach a wide belt at the center when lifting a roller. Avoid attaching chains
  or a wire to the rubber surface.
• Be careful of lubricating oil flying off onto a rubber roller surface. In case it happens, wipe it off immediately.
• Make sure the package is insured against damage and loss, All shipments by us are covered.

Storage Instructions

• Rollers should be stored at cool and dark places
• Do not remove UV paper from rubber roller,it helps prevent UV and ozone damage to finished product.
• When storing a rubber roller, hold at the shafts or stand the roller upright.
• Do not store them near electrical equipment such as a motor and Lamps.
• We recommend re-polishing rollers which have been stored for more than 6 months.
• For large and heavy rollers with soft rubber material, rotate the rollers at regular intervals to avoid curving or bending.

Setup And Usage Instructions

Mechanical Factors

• Wear-out of a bearing, an axis and a gear, unfair loading and machine shaking cause over wear-out of a rubber surface
  or shortening of a roller life time. Care should be taken for these factors. The same care should be taken for an unbalanced roller or a deflected roller.
• Load capability on a rubber roller should not exceed 60 kgf/cm in linear pressure. In case of high pressure the roller
  surface may fail.

Temperature

• Rapid Heating should be Avoided.
• The Maximum Highest temperature for use of each rubber material depends on the type of the elastomer used
  You may reach a temperature up to 150 degrees Celsius for a special compounded material.
• Silicone withstands higher temperatures up to 300 degrees Celsius.

Chemicals

• The chemical properties differ for each rubber material, If a roller is used in a special condition, please supply us the chemicals in use so that we will select the suitable rubber material for you.