The ESR spreader roller
At HESSENBRUCH Spreading Technology, ESR means "EcoStretchRoll". It is a newly patented development for spreading webs of endless material. The new system has been developed by the inventor of the brush spreader roller, Dipl.-Ing. Rolf Hessenbruch. It stands out with its simple, light-weight and high-efficiency spreading elements.
It is ideal for the film, paper, nonwovens and textile industries. Individual rubber rings equipped with spreading elements spread any common web. Soft, wrinkle-free and efficient - and running particularly smooth even at high line speeds. ESR spreader rollers are used successfully wherever gentle, unwrinkled guidance of various webs is needed.
Properties
Working principle
Specially shaped single spreader elements spread independently of each other. Each element has a movement tolerance that is not influenced by the adjacent elements, which leads to maximum overall spreading. The elements weight only 0.5 grams each. They react highly sensitive to the pressure of the web through which they incline slightly towards the roller end and thus perform the spread. 1,300 to 2,600 elements work per meter of the roller, depending on the roller diameter. This ensures perfectly gentle web handling and complete wrinkle removal.
Contact surface
The large, smooth and slightly curved contact faces of the individual spreading elements are made of the synthetic rubber EPDM, silicone or of TPE. They ensure a perfect grip for the lane. The high density of spreading elements and their contact with the web without any friction prevent marks and guarantee best protection.
Wrap angle
As a guiding roller, the ESR offers full function for wrap angles from 8 to 180 degrees, independent of the rotating direction.
Web tensions
Absolute wrinkle-freeness at a lane tension between 40 and 500 N per metre roller length. Web tension control is useful even though a wide range of tension is possible.
Web thickness
Outstanding results for all common material thicknesses - from films to textiles. Best results, e.g., for:
Biax PETP films >4 µm
Plastic films >8 µm
Fleeces (nonwovens) >10 g/m²
Multiple cuts
The arrangement and combination of the individual spreader elements is so variable that the spreading behaviour can be deliberately influenced across the roller width. This permits deflection of individual lanes in stripes without any problems.
Turning bar system
Just perfect. The ESR lives up even to the requirements of turning bar systems that oscillate by 360 degrees. Interfering influences are compensated by the roller and the web is kept perfectly wrinkle-free. According to expert opinion, the ESR roller offers the best results compared to other web spreading systems - e.g. brush spreader rolls or pure rubber rollers.
Line speed
The unique design of the individual spreading elements permits secure web spreading at line speeds of up to 800 m/min. The combination of vibration insulation of the soft rubber spreading elements and their installation on high-quality deflection rollers ensures a perfectly smooth, vibration-free operation even at high speeds.
Material properties
EPDM:
Modern rubber with very good usage properties such as temperature-resilience up to 110 °C, ozone resilience, wear-resilience, good antistatic behaviour.
TPE:
Similar properties as EPDM, additionally dyeable, recyclable, FDA compliant.
Silicone:
High temperature resilience up to 190 °C, low adhesion, easy dying, food-grade, FDA compliant.
Versions
The size, design, material and mounting arrangement of the individual spreading elements depends on the area of application and the production parameters.
4 outer diameters 60, 110, 130 and 150 mm are available in 3 materials - EPDM, TPE and silicone.
We distinguish 2 types in terms of function: BR (Basic Roller) and ST (Sensitive Treatment). The colour of the spreading rings can be customised upon special request. Roller lengths of up to 7000 mm can be realised according to individual customer requirements.
Roller body
Smooth-running roller from DRECKSHAGE. The lightweight aluminum core made of profiled tube guarantees high load capacity and bending strength due to its special geometry. The roller reacts very quickly due to very low starting weights from 20 g and low mass inertia.
Assembly
The prerequisite for mounting is a high-quality carrier roller. The carrier rings with the individual spreading elements are mounted and fastened on it.
The complete ESR spreader roller is produced to the customer's demand. It does not need any separate drive, which makes it ready for operation at once - without any further settings.
Working principle of the roll
Design
The ESR spreader roller is set up as follows: Individual spreader elements are placed on carrier rings. These spreading rings are installed on high-quality guiding rollers, with the rings being aligned from the inside out - in the spreading direction. Every spreading ring has 20 to 40 individual spreading elements, depending on diameter, that are perfectly independent of each other.
Approx. 65 spreading rings are needed per metre of roller length. Thus, about 1,300 to 2,600 individual spreading elements are in use per metre. With their minimum weight of 0.5 g in the deformable part, they react extremely sensitively even to very low web pressure.
The size, design, material and layout of the individual spreading elements is determined by the area of application and the production parameters. ESR spreader rollers are available in the 4 designs: 60, 110, 130 and 150 mm outer diameter.
Function
The individual spreader elements are deformed even by slight pressure in the spreading direction, and thereby produce a small shift by slightly shifting towards the roller end. They thus perform a small but very gentle and effective spreading movement. Since this happens 20 to 40 times per turn, it produces a soft but effective overall spreading effect – at an extraordinarily calm operation in spite of high line speeds.
Large contact faces avoid marks on the web surface, so that even highly sensitive materials can be spread wrinkle-free, easily and successfully.
Due to the low additional weight of 1 to 3.3 kg per meter, the ESR spreader rollers can be easily balanced and then mounted. Even at 800 meters per minute running speed, the web remains absolutely vibration-free.
