CALENDERING

Gireshesh Kumar G
2016110009
 Introduction

 It is a process of smoothing and compressing a

material (notably paper) during production by
passing a single continuous sheet through a
number of pairs of heated rolls.
 The rolls in combination are called calenders.
 Working
 The basic idea of the machine is that squishes a heat softened
polymer between two or more rollers (this area is called a
nip) to form a continuous sheet.
 To begin the process the polymer must go through blending
and fluxing before it goes through the calender.
 Blending is a process that creates the desired polymer mix
and fluxing heats and works this blended polymer to make it
much easier for the calender to handle.
 The polymer then go through the calender and will leave it at
a thickness depending mainly on the gap between the last two
rollers.
 The last set of rollers also dictate the surface finish;
for example, they can influence the glossiness and
texture of the surface.
 Rollers tends to follow the faster moving roller of the
two that sheets are in contact with because it can also
sticks more to the hotter rolls.
 Otherwise the sheets will split by sticking to both
rollers. This splitting phenomenon has forced
calender operators to desire a high friction ratio
between two rollers, which ranges from 5:1 to 20:1
Calendering
 Calender rolls are constructed of steel with a
hardened surface, or steel covered with fiber.
 In paper production, they typically exert a
pressure of 500 pounds per linear inch (89
kilograms per centimeter).
 Coated papers are calendered to provide a
smooth, glossy finish.
Calender with its types
 Effects
 Roll crowning: uses a roller that has a bigger diameter
in its center to compensate for the deflection of the
roller.
 Roll bending: involves applying moments to both ends
of the rollers to counteract the forces in the melt on the
roller.
 Roll crossing: the rollers are put at a slight angle to
each other and because of this the force of the rollers on
the melt is higher in the middle where the rollers are on
top of each other and less force is applied on the edges
where the rollers are not directly over top of each other.
 Uses
 Major plastic material is PVC are produced.
 Also produced are:
– Wall coverings
– Shower curtains
– Table covers
– Luminous ceilings
– Rubber sheets
 Industrial process used to produce:
– Car tires
– Conveyor belts
– Inflatable rafts
– Waterproof cloth tents
– Pressure-sensitive tape
Industrial Machine
 Advantages
 The best quality sheets of plastic today are
produced by calenders.
 It is good at mixing polymers that contain high
amounts of solid additives that don't get blended
or fluxed in very well.
 There is a large production compared to extrusion
for the amount of mechanical energy that is put
in.
 Defects

 Dimensional Non-uniformities – Thickness

variations in the sheets due to roll bending with
large separation forces. Compensated with crowned
rolls – larger diameter in center than at ends.
 Structural Anomalies – Particulate and crystalline
structure changes under the influence of high
temperature and stress
 The process also is not as good at too high of
gauges or too low of gauges.
Thank you!