The ESR spreader roller

At HESSENBRUCH Spreading Technology, ESR means "EcoStretchRoll". It is a newly patented development for spreading webs made of many different materials. 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 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 smooth, wrinkle-free guidance of different 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 sensitively to the pressure of the web through which they incline slightly towards the roller end and thus perform the spread. 2,000 to 2,600 elements work per meter of the roller, depending on the roller diameter. This ensures perfectly gentle web handling.

Contact surface

The large, smooth and slightly curved contact faces of the individual spreading elements are made of the synthetic rubber EPDM or of silicone. 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.

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.

3 outer diameters 110, 130 and 150 mm are available in 2 materials - EPDM and silicone.

We distinguish 3 types in terms of function: BR (Basic Roller), ST (Sensitive Treatment) and FP (Fast Performance). 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

The EconomicRoll® from DRECKSHAGE. The lightweight roller body made of aluminium profile 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

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 30 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 2,000 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 3 designs: 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 30 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 2 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.

Spreading of different materials

Films & Foils

The ESR spreader rollers are suitable for any film type from 4 μm upwards – both for single-layer films and for multiple-layer films or, e.g., Biax PETP films. The ESR system is perfectly suitable for use in a turning bar system. Type BR is great for films starting at 30 μm. Type ST ensures best results for very thin materials starting at 4 μm. Type FP is used for speeds in excess of 500 m/min.

Nonwovens

Fleeces from the nonwovens industry can be spread outstandingly well due to the unique properties of the ESR system. The large contact surface guides the web gently, so that even materials of 10 g/m² can be spread securely. Type ST is used at medium speeds of up to 500 m/min. Type FP ensures wrinkle-free web handling at higher speeds.

Fabrics

The ESR ensures a perfect spreading result for all kinds of textiles. The large contact surface permits gentle guidance of the material. The fabric cannot catch on the ESR roller. The ideal roller type for spreading and transverse stretching of textiles is type ST.

Papers

Paper can be spread particularly gently due to the large smooth contact surface made of EPDM or silicone. Both smooth and rough paper grades can be ideally spread with the ESR system. Type ST delivers the best results for thin paper grades and speeds up to 500 m/min. Type FP is the first choice for speeds up to 800 m/min.