EcoStretchRoll – a new, highly-efficient spreader roller for media such as foil, fleece, textiles or paper
EcoStretchRoll is a completely new kind of spreader roller. It was developed and tried by the inventor of brush spreader rollers. This new development aimed at considerably improving previous systems using precision rubber rings protected by filed and granted property rights. These rubber rings consist of many individual spreading elements ensuring excellent spreading behaviour already at low enlacement without any drive or adjustment at the roller. On the spreader roller, these rubber rings are assembled that way that they are adjusted in spreading direction from the centre outwards. Depending on the diameter, each precision rubber ring consists of 30, 36 or 40 individual spreading elements working absolutely independently from each other.
Each individual spreading element weighs just 0.5 grams and consequently reacts quickly to each product pressure. A special protected design of the spreading elements automatically provides for a controlled inclined displacement in the direction of the edge of the roller. These rubber rings are assembled at our factory on our proven EconomicRoll®.
Advantages of the EcoStretchRoll:
- Available in diameter 110 mm, 130 mm and 150 mm (roll shell 80, 100 or 120 mm)
- no functionless middle part
- Spreads as soon as spreading potential is available
- No external drive required; spreader roller is operated by the material web
- According to diameter just 2 kg, 2.3 kg or 3,2 kg additional weight per metre
- No marking on the media thanks to rounded spreading elements
- Versatillty, e.g. as an alternative for other spreader rollers or deflection rollers at critical points
- available in EPDM and silicone
Practical application examples:
VITO Irmen GmbH & Co. KG, Remagen
VITO Irmen produces single-sided or double-sided self-adhesive sealing tapes on the adhesive coating machine shown here. In this example, the final product comprises several components that need to be guided without creases into the gap between two lamination rollers. In the lamination station a strip of 8 mm thick PE soft foam is merged with a 15 µm thick PET film. The latter is already coated with adhesive on both sides; one of the adhesive sides is covered with a silconized protective film. The layer structure of the finished product is therefore: Soft foam, laminate glue, PET film, object glue, covering film. Using the laminate glue (a dispersion acrylate), the PET film is laminated tightly to the soft foam as a tensile reinforcement.
To feed the multi-layer composite of lamination adhesive, PET film, object adhesive and cover film into the delamination gap without creases, the previously used expander roller of a different type was replaced with the EcoStretchRoll by Dreckshage. The technical challenge in this machine was the very winding angle of just about 10 degrees. As the EcoStretchRoll creates an axial force from the centre to the outside as a result of its function even at very small deflection angles and even when there is only a tangential touch on one of the goods strips and therefore creates a spreading effect, the result is a continuous crease-free end product that fully satisfies the customer.
At this position, an expander roller is replaced by an EcoStretchRoll. It is installed in a turning bar system between the two turning bars. The medium being processed is a 60µm thick seven-layer film (barrier film). The film width is 1400mm and is moved at a speed of 70 m/min.
In this installation position the requirements made of the expander roller are very high. According to the customer report, crease-free production of all widths is only possible with the EcostretchRoll.
This video shows an EcoStretchRoll installed in a Double Bubble extrusion system. A biaxial elongated barrier film that is 50µm thick is stretched. The film width is 300 mm and is moved at a speed of 30 m/min.
Due to the production process, it is difficult to move the film without creasing it; however this is not a problem with the EcostretchRoll.
INNO Tape GmbH, Alfeld (Leine)
The EcoStretchRoll from DRECKSHAGE is used in various applications in which various materials are used. Users can produce and process films and non-wovens, textiles or paper with the same expander roller. Mr Tschorn from the company INNO Tape GmbH reports about the successful use of the EcoStretchRoll.
EcoStretchRoll expander roller used by INNO TAPE GmbH, Alfeld (Leine)
We use self-adhesive materials from reputed manufacturers as converters, and process these in line with our customer’s requirements.
To achieve a flawless result, all materials that are being processed must be prepared perfectly. We prepare an adhesive tape with a carrier for the cutting process on one of our winding machines. According to the customer’s wishes, this is wound to a specific length. "In the past we kept encountering problems with a material. The faulty winding by our supplier was insufficient for our processes. Unfortunately, this only becomes evident after cutting by means of air inclusions and telescopic rollers. Our customers could not process rolls with this error pattern."
To achieve a better final result, the material must be wound first. However, it was clear that this alone would not be enough to get the air out of the material without causing creases. Here, the company DRECKSHAGE helped and quickly delivered an EcoStretchRoll in the right width that can be integrated into the system easily and simply. This led to flawlessly wound rolls without air inclusions.
As other pullers can now be used, we now have an optimum winding quality and as a result, a perfect end result after cutting.