Professional Documents
Culture Documents
CALENDERING PROCESS
BASIC PRINCIPLE
Sheet
The sheet is then trimmed to required width and wound on a tube or cut
to length and stacked as sheets.
Precautions to be taken
during processing
Preparation of stock for calendering, conditions on the
calender, the take off, thickness measurements, and
control to wind up.
Other considerations include whether the plastic is
laminated to a fabric on the calender.
Types of calenders
Z type of Calenders
Types of calenders
Z type calender has the advantage that bending of
the rolls caused by pressure of material in the nip
has no effect on the succeeding nip and therefore
tends to improve thickness accuracy.
The inverted L offers a good compromise, since
the first pair of horizontal rolls hold the input
material easily succeeding two nips can be
arranged to give good control
- Type
The hot oil can be circulated through the rolls to achieve the high
operating temperature.
Processing Parameters
The processing parameter needs to be set and control are
temperature, speed, pressure and the nip gap.
Examples:
Roll No.
Roll Temp.(C)
Speed( m/min.)
1st
165
80
2nd
168
82
3rd
171
85
4th
174
88
Nip gap between rollers:
Roll No.
Nip Gap
1st - 2nd High
2nd -3rd
3rd -4th
Medium
Low
TABLE 1
Roll No.
Roll Temp. (C)
1st 145-150 75-80
2nd 150-155 80-82
3rd 155-160 83-85
4th 160-165 85-90
Speed ( m/min.)
Roll
3
Nip gap
low
Roll
2
Roll
4
Nip gap
between rolls
Roll No
1-2
2-3
3-4
Nip Gap
High
Medium
Low
The calender lines during operation generate very high forces exerted on
the rolls to squeeze the plastic melt into a thin web or sheet.
Crossing the rolls slightly, thus increasing the nip of opening at either end of
the rolls.
Troubleshooting in calendaring
process
Faults
Causes
Compound formulation
Poor gauges
Improper temperature
Improper compound
Improper flow
Streaks
Poor compounding
Improper temperature
Contamination
Thickness variation
Discoloration
PVC
Applications