Because work translates into resulting excellence thanks to the use of innovative solutions and cutting edge products
Reglass acts as a problem solver thanks to its ongoing collaborative research activities with universities and institutions, as well as its close collaboration with resin and fiber suppliers.
Thus it became partners with its customers in the development of customized solutions aimed at improving the quality and productivity of their systems.
For this reason it chooses to also assist niche markets that aim for high quality: a distinctive and successful corporate policy that is still upheld today.
Carbon composite rollers are made using Wrapping technology. They are designed to ensure high quality standards and meet the needs of operational simplification, flexibility of use, and to reduce production costs. These rollers that, due to their size and technical features, address the needs of companies to create converting systems that are competitive and diversified.
Production efficiency, consistent quality and rapid changes in manufacturing are the most important features in the machinery sector for flexographic and rotogravure. There are various possibilities for the application of carbon rollers on these machines:
- In both printing technologies it’s possible to replace a good part of the idle rollers and to manage with rollers of composite carbon fiber material. Given their low inertia, they ensure a soft dragging without stress or scratches on the printed film, and therefore a final product of excellent quality.
- With flexographic printing it’s possible to substitute printing and anilox steel cylinders with carbon portamaniche This can greatly increase the speed and printing requirements, especially with difficult stereotypes.
Rollers intended for digital printing have recently been introduced. Their small dimensions allow for the production of extremely reduced batches.
Clichè rollers and air mandrels
Around these the printing process turns. A carbon fiber spindle (also with the standard elastic form) represented a substantial innovation in comparison to the steel spindle. Equal in stiffness, it has in fact a decidedly lower weight, allowing it to obtain a much higher frequency. Even better working is the carbon spindle with high elastic modulus. In addition to reducing weight, it increases rigidity, as opposed to steel. Reglass builds portacliché cylinders and portamaniche spindles, with diameters up to 420mm and table lengths up to 6m.
They receive ink from the reservoir through the blade, transfering it to the stereotype in a uniform manner. Normally they are subjected to a complex exchange of stresses, triggered by the vibrations of the stereotype cylinder. Thanks to Reglass technology these are greatly reduced, thereby avoiding repercussions in the distribution of the ink, with the added advantage of lower wear and tear. Reglass produces anilox rollers which, together with clichè rollers, enable unsurpassed performance in flexographic printing.
These are applied to all machines for the processing of plastic film, paper, tissue and nonwoven materials. Carbon rollers are optimal in this field, ensuring efficiency and speed, while avoiding vibrations which, for these systems, must be very stiff and light. The critical speed of the roller, together with a reduced arrow under the tension of the film, is essential to ensure a high working speed for the system.
One often finds that for lights of more than 2.5m only carbon fiber and Reglass technology are able to ensure the weights, stiffnesses and critical speed adequate for the demands of high productivity. It would be unthinkable with the use of other materials.
Reglass builds converting rollers with diameters up to 420mm and lengths up to 6m.
A comparative example between an aluminum product and a carbon composite Reglass roller:
Shafts are suited to the winding and unwinding of coils with cores, in all processes of converting. They can also be used for multiple coils, provided they have widths greater than 200mm. They have the advantage of weighing much less than their corresponding steel models, and can easily be moved about by one person, with substantial benefits to productivity.
The body of the expanding shaft is made of high strength carbon and produced with Wrapping technology. It is the only technology that allows for maximum compactness of fibers to obtain the best performance from the composite materials. The surface coating is always carbon fabric, ensuring extremely high resistance to wear and tear. The metal ends of the shaft are characterized by a special joining system of metal-carbon. The modular design allows it to adapt to machines made to customer design.
The shafts can be supplied in two versions: the first for heavy loads, and the second for high speeds with loads substantially reduced.
The standard diameter is 3″, the table lengths are from 800 to 2.500mm and greater.
Reglass executes a variety of other tubular products in carbon to be used in many industrial sectors. These production designs are based on specific performance needs, which are only made possible thanks to the use of carbon composites. For the construction of individual products, Wrapping and other exclusive technologies are used.
The following are areas of application and some actualized examples.
The new high technology sliding bearings are specifically designed to support heavy loads, comparable to those of steel. They meet the demands of high speeds, and are suitable to be used in productions of great mechanical precision.
Thanks to the carbon structure it’s possible to obtain the absence of mechanical play between the shaft and the sliding surface. They have a life span far superior to the corresponding steel bushings covered in bronze, bronze-graphite, or sintered, and have excellent heat dispersion. They are fabricated using a composite structure consisting of long high resisitant carbon fibers, with a high elastic modulus. Inside there is a layer of Ptfe loaded with micro-particles and firmly attached to the composite through an exclusive technology developed by Reglass.
Fields of Use
- Earth-moving equipment
- Aeronautical applications
- Naval applications
- Mechanical applications with heavy loads
- Mechanical applications with high accuracy