03 Machinery and equipment for the plastics and rubber industries
03.11 Parts and components
Product category: Calenders
Rodolfo Comerio's Calenders for Plastics
It is the most prestigious production and covers the whole range of materials that can be calendered: S-PVC, E-PVC, ABS, PP, PET, TPO.
The high precision calenders, “I”, “F” or “L” shaped, with 2, 3, 4 or 5 rolls, rotating on bearings without clearance, are provided with special post-calenders featured by high efficiency small rolls.
Highly sophisticated winders granting an extremely precise tension control on the film, suitable to wind up small or big diameter ranges of single or multiple bobbins, complete the lines.
Specific post-calenders for: - Clear soft films - Laminated coloured soft films - Glossy lacquered soft films - Reinforced films for flooring - Rigid and semi-rigid films for printing - Rigid films for thermoforming - Rigid films for pharmaceutical industry - Bioriented rigid films for adhesive tapes
RODOLFO COMERIO calendering lines for rubber, traditional and sturdy, benefit more and more from the achieved remarkable improvements and continuous development, that have led to the current annual production capacity of more than 20 calendering plants per year.
The high output calenders are “I”, “S” or “F” shaped, with 2, 3 or 4 rolls, rotating on bearings without clearance, and are provided with pre and post-calenders optimized to achieve any peculiar technological requirement.
Lines differ because of the final production and includes: - Steel cord calendering lines PCR – TBB – TBR – OTR – aircrafts - Textile cord calendering lines PCR – TBB – TBR – OTR – 2/3 wheels – aircrafts - Combined calendering lines for textile/steel cord PCR – TBB – TBR – OTR – 2/3 wheels – aircrafts - Innerliner calendering lines provided with 2+2 rolls - Rubber sheeting calendering lines - Profiling calenders - Calendering lines for rubber strips - Calenders for rubber bands - Calendering lines for conveyor belts - Calendering lines for printing blankets - Calendering lines for air springs - Calendering lines for high pressure pipes rubberized materials - Oversize calendering lines for special applications - Special roller head and roller die calenders - Calendering lines for adhesive tapes materials - Special calenders for asbestos-free gaskets - Rubber laminating lines - Automatic winding and unwinding machines
Machines designed to guarantee high performances both from speed and quality point of view allowing a continuous winding tension control.
The winders produced by RODOLFO COMERIO are suitable to wind up all kind of plastic film, such as: · Rigid, semi-rigid and flexible PVC sheet of different thickness · PVC sheet laminated to any type of reinforcing material, paper, fabric, fiber glass · Rubber sheets and profiles · Rubber sheets laminated to textile and steel cord
The range of is extremely wide and goes from simple winders with manual material cutting to turret winders provided with completely automatic cutting device.
Machines designed to be installed in the calendering lines for plastics and rubber production or to be used in series in mixing rooms or separately, they all involve the fundamental principles of sturdiness, manoeuvrability and economy.
These principles are exalted by the use of steel frames and rolls, provided with self-aligning bearings, driven through reduction gears and independent universal joints or through hydraulic motors, and equipped with attachments purposely designed to eliminate any manual procedure.
These roll mills are suitable to: - Act as a lung in calendering lines for plastics - Automatically prepare the rubber compound in the mixing rooms. SSMSystem (Single Step Mixing System) - Act as crackers and feeders of rubber calendering lines - Mix special products such as silicone, asbestos, medical products, plastics and rubber in general
Machines suitably designed to allow the packaging of the rolls guaranteeing high output speeds maintaining full quality control with significant savings in term of labour costs.
These machines are perfectly suitable for quality control, cutting, automatic winding and packaging of PVC reels or other materials, single or laminated with other sheets, or with fabrics of different nature or paper.
Final packaging of the reels can be performed in different ways: · with plastic film or paper sheet, automatically unwound and cut · with shrinkable film which wraps up the roll at the outlet of rereeling machine. · by sealing the material end-tail by means of sprayed adhesive before rolling up the last material centimetres.
Phases of material threading up, winding with established length, sheet cutting, loading of the new cardboard core, packaging and storage follow a completely automatic cycle, with high output speed and total guarantee of constant tension and non-deformability of the sheet.
Winding is performed either by means of contact winding through a contact roll or by spindle axis control or using both systems.
Technical data Diameter of the reel to be unwound – 1500 mm Maximum reel diameter wound in contact – 500 mm Maximum reel diameter wound axially – 1000 mm Diameter and width of winding cores - variables Number of wound reels on core - variable Cutting sequence time - < 1 min
RODOLFO COMERIO proposes its exclusive and Patented system able to perform the embossing in register of any kind of material (extensible or reinforced).
This aim is achieved thanks to an highly innovative laminating and embossing line that allows to: · Continuously unwind and automatically cut and join different materials to be laminated · Center them · Preheat them by means of infrared heaters · Continuously laminate them · Emboss the back surface of the obtained laminated material · Emboss in register, by keeping in synchrony the pattern of the printed film with the engraving of the embossing roll · The embossing unit is furthermore provided with a revolving device allowing the quick change of the engraved roll, minimizing production interruption and consequently the scraps. · Cool the laminated and embossed material · Trim, cut and stack the slabs
This type of equipment is suggested for products that require high stability and quality and for a maximum variety of treated items.
It is designed for hot lamination of up to six sheets or combined lamination using adhesives in one single work process and for subsequent embossing.
The heart of this type of equipment is the gradual and independent heating of each sheet on small diameter rolls, placed in very closed proximity, with specific surface finish and internal construction, appropriately driven, heated and cooled in order to provide the sheet with the best laminating conditions.
The sheets are laminated one by one with very wide entry angles to avoid air inclusions with the heating process being completed on other, small diameter rolls.
The material is embossed in a vertical position, after a final heating process with an infrared unit for adjustable and graduated heating across its width and length, with the engraved and rubber rolls designed to obtain the best thermal exchange between fluid and sheet, the absolute temperature accuracy and minimum possible flexions across the entire width.
Efficient control units for adjusting tension and the temperature, in addition to the subsequent sheet take-off, stabilizing and cooling rolls guarantee the production of a perfectly laminated material without any tension or with no air inclusions, with increased engraving speed and accuracy, perfectly flat and with no elastic memory
The remarkable production rates and the high efficiency of these equipment make the production of a wide range of products possible: • Thickness range of the materials to be laminated - 0,06 - 1,2 mm • Thickness range of finished products - 0,5 - 2,5 mm • Film width more than - 2.500 mm • Line speed higher than 50 m/min
Rodolfo Comerio is the oldest company in the World in manufacturing complete plants for Plastics and Rubber sheet. With the current annual capacity of 25 calendering plants for PVC and RUBBER, besides other lines and machines completing our wide production range, RODOLFO COMERIO is the leader Italian company for the manufacturing of laboratory mills, 2-roll mills, roll calenders for the lamination of thermoplastic films (Calendering lines for Plastics, Laminating, Embossing and Rotogravure Printing lines, Automatic Rewinding machines for Plastics, process KNOW-HOW for Plastics lines) and rubber sheets (2/3/4 roll calenders and complete calendering lines for steel cord rubberizing for PCR, TBR, OTR radial and giant tires, textile cord rubberizing for industrial and car tires, fabric rubberizing for printing blankets, life rafts, air springs, folding bellows, conveyor belts, plates and sheets rubberizing for technical applications…), proud that 100% of its products is exclusively made in Italy.