Product innovation 1Z14. The latest generation sponge rubber roll cover.
Ing. Federico Barsanti, SchäferRolls Sales Engineer Italy
Sponge rubber is an ideal material for roll covers in various applications. In fact, its physical properties offer a variety of useful benefits. Thanks to its special cell structure, sponge rubber has low-weight, compression and resilience properties which make it ideal for demanding applications requiring flexible shape characteristics as well as excellent shock and vibration absorption. In addition, roll covers made of sponge rubber are especially well suited to applications requiring wide and uniform nip conditions and compensation for profile deviations.
SchäferRolls, a long-established leader in the production of high-tech sponge rubber materials, is pleased to present its brand new 1Z14 solution: an innovative sponge rubber product which, in addition to the aforementioned characteristics, adds excellent mechanical properties and – in combination with an improved bonding technology – is able to operate reliably under the most severe conditions.
The 1Z14 solution consists of a mixture of polymers designed and produced by SchäferRolls. During the polymerization reaction they are able to create a very fine and homogeneous mixture of closed cells thanks to special catalysts.
This material is not bonded directly to the shell but uses Hybriflex multi-layer technology, i.e. with an innovative auxiliary bonding system called C.protect based on special reinforced composite materials.
The result is incredible: a soft material (hardness 30 P&J), elastic and resilient, totally antistatic, with high thermal (up to 130° C) and mechanical resistance as described below.
1Z14 as rider roll cover on a winding machine
In fact, in autumn 2020 a well-known Italian paper mill called in SchäferRolls’ specialists to solve long-standing problems with sponge rubber rider roll covers breaking on its winding machine. Due to structural problems, the machine
generates high vibrations and the best covers on the market allowed a cover lifetime of no more than 6-12 months due to continuous breakages.
Smooth and reliable running of the rider roll is decisive for an optimum winding process. Rider roll covers have to offer excellent damping properties, uniform nip conditions and mechanical stability throughout their complete service
life. The application therefore provided the perfect test bench for the new 1Z14!
In February 2021 the first rider roll with the SchäferRolls 1Z14 cover was installed in the machine, and the customer immediately noticed a reduction in vibration and excellent compression reset following mechanical impact.
To date, after more than one and half years in operation, not only are there no breakages or damage to the cover, but material wear is below 1 tenth of a mm. The outcome: a significantly higher cover lifetime, excellent winding results
and a stable winding process.
The new 1Z14 sponge rubber roll cover from SchäferRolls is therefore an ideal solution for reel drums and rider roll covers of winding machines and for all those applications where excellent absorption of vibration and mechanical
shock, excellent compressibility and high mechanical stability are required.
