ODM Or OEM 2, 3, 4 Roller Rubber Calender With High Quality And Fast Delivery
 

Differences between Two-roller calender and Three-roller calender

I. Roller structure and material transmission method
Two-roller calender
The structure of the two-roller calender is relatively simple, mainly composed of two rollers rotating in opposite directions. The rubber material is sent to the gap between the two rollers through the feeding device. Material transmission mainly relies on the friction between the two roller surfaces and the rubber material. For example, when the rubber material contacts the rotating roller, it is rolled into the gap between the rollers under the action of friction and transported forward as the rollers rotate. This transmission method is relatively direct and is suitable for some simple calendering operations that do not require particularly high thickness accuracy and have a relatively regular shape of the rubber material.
Three-roller calender
The three-roller calender has an upper roller, a middle roller and a lower roller. Its material transmission process is more complicated. The rubber material can enter between the rollers from two positions. A common method is that the rubber material first enters between the upper roller and the middle roller, and then passes between the middle roller and the lower roller before being output. In this process, the rubber material is initially calendered and transmitted between the upper roller and the middle roller, and then further calendered and adjusted in shape between the middle roller and the lower roller. Due to the synergistic effect of three rollers, the three-roll calender can better control the flow direction and shape of the rubber material, making the rubber material more evenly distributed during the calendering process.
 

II, Calendering effect and product quality
Two-roll calender
The calendering of the rubber material by the two-roll calender is mainly a one-time extrusion process. Because there are only two rollers, the rubber material is calendered after passing through the gap between the rollers. This method is relatively difficult to achieve high precision in thickness control. For example, if you want to produce thin sheet rubber products with very uniform thickness, the two-roll calender may cause a certain deviation in thickness due to the uneven flow of the rubber material in the gap between the rollers. However, for some rubber products that do not have strict thickness requirements, such as some rough rubber pads, the two-roll calender can meet the basic calendering needs.
Three-roll calender
The three-roll calender can more effectively control the thickness and surface quality of the product through two calendering processes. The first calendering between the upper roller and the middle roller can preliminarily adjust the thickness and shape of the rubber material, and the second calendering between the middle roller and the lower roller can further refine it. This makes the rubber products produced more uniform in thickness and smoother in surface. For example, when producing the cover layer of high-quality rubber conveyor belts, the three-roll calender can better ensure the uniformity of thickness and surface flatness of the cover layer, thereby improving the quality and service life of the conveyor belt.
 

III. Adaptability to rubber and processing range
Two-roll calender
Due to its simple structure, the two-roll calender has certain limitations in its adaptability to rubber. It is more suitable for processing some rubbers with relatively low viscosity and relatively soft texture. Because for rubbers with high viscosity or complex ingredients such as more fillers, the two-roll calender may not be able to effectively make the rubber pass through the roller gap evenly, and it is easy to cause rubber accumulation or uneven calendering. In terms of processing range, the two-roll calender is mainly used for some simple rubber sheet calendering, preliminary mixing of rubber and simple laminating operations.
Three-roll calender
The three-roll calender has a stronger adaptability to rubber. It can process rubbers of various viscosities and complex ingredients. Due to its special structure with three rollers, it can better cope with the complex rheological behavior of rubber during calendering. For example, for rubber containing fiber-reinforced materials, the three-roll calender can better distribute the fibers in the rubber while ensuring the calendering quality of the rubber. In terms of processing range, in addition to being able to produce high-quality rubber sheets, the three-roll calender is also widely used in the lamination of materials such as rubber and fabric, rubber and steel wire, and the production of parts for complex rubber products such as tires and conveyor belts.

Working principle and characteristics of calender:

Working principle
Roller arrangement and material entry
Common roller arrangements for 4-roll calenders include L-type and Z-type. Taking the L-type as an example, the rubber material is first fed to the gap between the first and second rollers by the feeding device. The rollers rotate synchronously and in opposite directions, and the rubber material is rolled into the gap under the friction of the rollers. This process is similar to the initial feeding principle of the double-roll and three-roll calenders.
Multiple calendering processes
After passing through the gap between the first pair of rollers, the rubber material is initially calendered and changes its shape. Then, it enters between the second pair of rollers for further calendering. For example, in an L-type 4-roll calender, after the rubber material comes out of the first and second rollers, it will enter between the second and third rollers or between the third and fourth rollers (depending on the specific process requirements). Each calendering will further reduce the thickness of the rubber material, further expand the width, and make the molecular chains inside the rubber material more orderly.
Working with auxiliary devices
The 4-roll calender is also equipped with auxiliary equipment such as feeding devices, traction devices and temperature control systems. The feeding device ensures that the rubber enters the gap between the rollers evenly and stably, and the traction device pulls out the calendered material at an appropriate speed to prevent material accumulation or over-stretching. The temperature control system changes the fluidity of the rubber by adjusting the roller temperature, so that the rubber can better adapt to different process requirements during multiple calendering processes and ensure product quality.
Features
High-precision product thickness control
Due to the four rollers squeezing and shaping the rubber, the 4-roll calender can produce rubber products with very high thickness accuracy. Compared with the double-roll and three-roll calenders, it can more accurately calender the rubber to a very thin thickness and maintain uniform thickness. For example, in the production of some high-precision rubber films for electronic equipment sealing and other fields, the advantages of the 4-roll calender are very obvious, and the thickness error of the rubber film can be controlled within a very small range.
Good product quality and surface finish
After multiple calendering, the internal structure of the rubber is more uniform and the surface is smoother. The rubber products produced by the 4-roll calender have a high level of surface quality and can reduce surface defects such as wrinkles and bubbles. This is very important for the production of high-quality rubber conveyor belts, rubber seals and other products with high surface quality requirements. For example, when manufacturing the airtight layer of high-end automobile tires, the 4-roll calender can ensure that the surface of the airtight layer is flat and smooth, thereby improving the overall quality of the tire.
Complex process adaptability and versatility
The 4-roll calender can adapt to a variety of complex processes. It can not only be used for simple rubber compound calendering, but also for composite calendering of rubber and multiple materials. For example, when producing rubber-fabric-rubber multi-layer structure products (such as waterproof membranes), the 4-roll calender can well fit the rubber and fabric tightly while ensuring the thickness and quality of each layer. Moreover, by adjusting the parameters such as roller speed, temperature and gap, different calendering processes can be achieved to produce rubber products with different shapes, thicknesses and performance requirements.
High production efficiency
Although the 4-roll calender has a complex structure, it can complete multiple calendering steps in one process, reducing the time of repeated processing. Its production efficiency is relatively high when mass-producing high-precision and high-quality rubber products. For example, when producing large rubber sheets for industrial shock absorption and other purposes, the 4-roll calender can quickly calender the rubber into the required sheets and ensure that the quality of the sheets meets the requirements.

Technical Parameters:

1. Roll Arrangement
   • 4 - roll rubber calenders usually have different roll arrangements such as L - type or Z - type. The specific arrangement affects the flow path of the rubber material during the calendering process and determines the sequence of multiple calendering operations.
2. Roll Dimensions
   • Diameter: The diameter of the rolls typically ranges from [X] mm to [Y] mm. For example, a common roll diameter might be 300 - 600 mm. The roll diameter affects the contact area with the rubber material and the pressure exerted during calendering. Larger diameters generally provide more stable calendering and better material distribution.
   • Length: The length of the rolls usually varies from [A] mm to [B] mm. A typical roll length could be 800 - 2000 mm. The roll length determines the maximum width of the calendered rubber product.
3. Roll Gap Adjustment
   • The gap between adjacent rolls can be adjusted to control the thickness of the calendered product. The adjustment range is generally from [minimum gap] mm to [maximum gap] mm, such as 0.1 - 10 mm. Precise adjustment of the roll gap is crucial for producing rubber products with accurate thicknesses.
4. Working Speed
   • The working speed of the calender can be adjusted within a certain range. The typical working speed range is from [low speed] m/min to [high speed] m/min, for example, 2 - 20 m/min. The working speed affects the production efficiency and the quality of the calendered product. Higher speeds can increase production output, but may require more precise control to ensure product quality.
5. Motor Power
   • Each roll is usually driven by an individual motor. The power of each motor typically ranges from [power of each roll motor] kW to [higher power value] kW. The total motor power of the 4 - roll calender depends on the power of each roll motor and is generally in the range of [total power range] kW. Sufficient motor power is required to ensure the smooth rotation of the rolls and the effective calendering of the rubber material.
6. Product Thickness and Width
   • Thickness Range: The calender can produce rubber products with a thickness range from [minimum thickness] mm to [maximum thickness] mm, such as 0.05 - 5 mm. This wide thickness range enables the production of various rubber products, from thin films to thick rubber sheets.
   • Width Range: The width of the calendered products can generally range from [minimum width] mm to [maximum width] mm. The width is mainly determined by the length of the rolls and the feeding and guiding mechanisms of the calender.
7. Temperature Control
   • The rolls of the 4 - roll calender usually have a temperature - control system. The temperature - control range of the rolls is generally from [low temperature] °C to [high temperature] °C, such as 20 - 100 °C. By adjusting the roll temperature, the viscosity and plasticity of the rubber material can be controlled, which is beneficial for the calendering process and the quality of the final product.
8. Feeding and Traction
   • Feeding Device: The capacity of the feeding device is usually measured in kg/h. It can range from [low capacity] kg/h to [high capacity] kg/h, for example, 50 - 500 kg/h. A reliable feeding device is essential for ensuring a continuous and stable supply of rubber material to the calender.
   • Traction Device: The speed of the traction device is generally in the range of [traction speed range] m/min. It is used to pull the calendered product out of the calender at a proper speed to prevent material accumulation or over - stretching.
9. Overall Dimensions and Weight
   • The overall dimensions of the 4 - roll calender, including length, width, and height, are typically [length] mm×[width] mm×[height] mm. The weight of the calender usually ranges from [minimum weight] kg to [maximum weight] kg. These parameters are important for the installation and layout of the calender in the production facility.
10. Precision of Thickness Control

• The precision of thickness control is usually expressed as ±[precision value] mm. For high - precision 4 - roll calenders, the thickness control precision can reach ±0.01 mm. This high - precision control is crucial for producing rubber products with consistent and accurate thicknesses.

11. Maximum Pressure on Rolls

• The maximum pressure that the rolls can exert on the rubber material is usually measured in N/mm². The value generally ranges from [minimum pressure] N/mm² to [maximum pressure] N/mm². The maximum pressure affects the density and quality of the calendered product.