F-Type 3-Roll Rubber Calender Machine with 500mm Cylinder Diameter 10kW Power and 1000mm Roll Length for High-Quality Composite Rubber

What is an F-Type 3-Roll Calender?

The "F-Type" refers to the arrangement of the rolls. In an F-type configuration, the three rolls are arranged in a vertical or near-vertical line, resembling the letter "F". The material typically feeds between the top and middle rolls and exits from the bottom (between the middle and bottom rolls).

The "3-Roll" means it has three massive, precisely machined cylinders that rotate in opposite directions to squeeze, smooth, and thin the rubber compound into a continuous sheet.

Key Features and Advantages for High-Quality Composite Rubber

1. Superior Sheet Quality and Dimensional Accuracy:

• Precision Roll Grinding: The rolls are ground to extremely tight tolerances, ensuring perfect cylindricality and surface finish. This eliminates thickness variations.

• Roll Bending Compensation: Modern F-type calenders are equipped with Roll Bending Systems (e.g., hydraulic cross-axis adjustment). This counteracts the natural "bowing" of the rolls under the immense pressure of the rubber, ensuring a perfectly uniform sheet thickness across its entire width.

• Controlled Nip (Gap): The gaps between the rolls (nips) are micro-adjustable, allowing for precise control over the final sheet thickness.

2. Excellent for Composite and Laminated Structures:

• The primary advantage of a 3-roll calender is its ability to perform "Friction Coating" or "Topping".

• Process: A fabric (like nylon, polyester, or steel cord) is fed through the top nip. Simultaneously, a warm, soft rubber compound is fed into the same nip. The speed of the top and middle rolls can be set at a differential (friction ratio), forcing the rubber to penetrate and coat the fabric weave thoroughly.

• The now rubber-coated fabric then passes through the bottom nip, where a second rubber sheet can be laminated onto the other side, or it is simply sized to the final desired thickness with a perfect surface finish. This is essential for products like conveyor belts, tire carcasses, and inflatable rafts.

3. Efficient Heating and Cooling:

• The rolls are cored and designed as heat exchangers. They can be heated with steam, hot water, or thermal oil to a specific temperature profile.

• Why this matters: Precise temperature control is vital for compound viscosity. A hot roll keeps the rubber soft and pliable for processing. A cooler roll can be used at the final nip to "set" the sheet and prevent it from sticking, a process known as "airing" the sheet.

4. Robust Construction and Control:

• Built with a massive, rigid frame to withstand tremendous separating forces without flexing.

• Driven by powerful, variable-speed motors that allow for precise control of roll speeds and friction ratios.

• Integrated with a Programmable Logic Controller (PLC) and Human-Machine Interface (HMI) for storing recipes, automating the process, and ensuring repeatability.

• Technical parameters

Typical Process Flow in an F-Type 3-Roll Calender

Let's visualize the process for making a fabric-reinforced composite rubber sheet:

1. Pre-Feeding: The rubber compound is pre-warmed in an extruder (roller die head) or on a 2-roll mill and fed continuously into the top nip.

2. Fabric Insertion: The fabric substrate is fed into the same top nip, between the rubber compound and the middle roll.

3. Coating (Top Nip): The rubber is forced into the fabric weave under heat and pressure. A speed differential between the rolls enhances penetration.

4. Lamination/Sizing (Bottom Nip): The coated fabric passes to the bottom nip. Here, it can be calendered to its final gauge. Optionally, a second layer of rubber can be fed into this nip to create a symmetrical laminate.

5. Take-Off and Cooling: The finished composite sheet is stripped from the bottom roll by a high-precision take-off conveyor. It then passes over a series of cooling drums to bring its temperature down, stabilizing the dimensions and preventing blocking (sticking to itself when rolled up).

Comparison with Other Calender Types

• Inverted L-Type (4-Roll): More common for simple sheeting and plastic films. Excellent for thickness control but less straightforward for the friction coating process of a 3-roll F-type.

• Z-Type (4-Roll): The rolls are arranged in a Z-pattern. This design minimizes roll deflection without complex bending systems because the separating forces are more in line with the frame. Excellent for very wide, high-precision sheets but can be more complex for fabric coating.

Summary: Why it's Ideal for High-Quality Composite Rubber

The F-type 3-roll rubber calender is the machine of choice because it uniquely combines three critical functions in one continuous, automated process:

1. Precision Sheeting: It produces a rubber sheet with exceptional thickness uniformity and surface quality.

2. Fabric Coating: Its design is inherently suited for forcing rubber into a fabric substrate, creating a strong, void-free bond.

3. Laminating: It can easily combine multiple layers of rubber and fabric into a single, high-performance composite structure.

This makes it an indispensable asset in manufacturing high-tech rubber products where consistency, strength, and precision are non-negotiable.

Qingdao Beishun Environmental Protection Technology Co., Ltd. is engaged in Environmental protection machinery, rubber machinery R & D and manufacturing enterprises, located in the west coast of Qingdao ---- Jiaonan city, Qingdao Economic and Technological Development Zone, adjacent to the former Bay near Qingdao Port and International Airport Jiaodong airport, excellent geographical location.

The company gathered a large number of the industry's outstanding technical and management personnel, advanced machining, heat treatment equipment and sophisticated detection equipment. With high-quality service, advanced equipment and strong technical force as the basis, through constant innovation and development, Beishun Environmental Protection Technology machinery has many customers at home and abroad to establish a stable business relationship, and gradually establish a brand in the same enterprise.

Companies adhere to the "first-class quality to gain market confidence, quality service to win customer satisfaction, continuous improvement of enterprise development seek to establish a corporate brand management excellence" business philosophy, in terms of quality, brand and work hard to achieve the strategic goals of common development.

Qingdao Beishun Environmental Protection Technology Co., Ltd. will carry forward the "realistic, innovative, rigorous and efficient" business style, good governance, integrity first, with a high sense of responsibility "in customer service, service to the community", with industry colleagues mutual benefit, for a better tomorrow.