Rubber-coated counter-pressure roller for embossing units
In the production of plastic film and tissue (paper industry), achieving a consistent, well-defined embossed satin effect requires a perfectly balanced pair of rollers: on one side the engraved metal roller, which carries the pattern; on the other, the counter-pressure roller, which must match its pressure by transferring the pattern onto the final product without compromising its integrity. This is where the right coating makes the difference.
Our counter-pressure roller is designed for metal embossing units used in the processing of plastic film and tissue available on the market.
The coating is made with a specific double-layer compound, a specific construction solution designed to optimize the roller’s elastic recovery during the embossing cycle:
- Functional double layer: the two-layer structure allows stresses to be distributed differently between the support layer and the layer in contact with the engraved roller, improving overall elastic response and service life.
- Hardness from 45 to 60 ShA: the available hardness range allows selection of the compound best suited to the type of film and tissue, the thickness, and the required embossed satin effect, from softer hardness values, which favor a deeper, more enveloping impression, to stiffer ones, suited to sharp, high-definition embossing.
- Optimized elastic recovery: the double layer reduces the hysteresis phenomenon typical of rubbers subjected to repeated compression cycles, ensuring that the roller quickly recovers its geometry after each pass, without losing pressure uniformity throughout production.
The compound we offer maintains stable mechanical characteristics even under prolonged exposure to the heat generated by contact with the metal roller:
- Dimensional stability under heat: no deformation or swelling even after continuous high-temperature cycles.
- Resistance to thermal aging: the compound’s chemical structure slows down oxidation and hardening, preserving the designed hardness values (45-60 ShA) over time.
- Consistency of the embossed satin effect: the surface of the counter-pressure roller maintains its compactness and regularity even after intensive use, avoiding loss of definition in the pattern transferred to the film and tissue
In the embossing process, the plastic film and tissue reach, under pressure and heat, a state of plasticity that allows them to receive the pattern from the engraved roller. The rubber-coated counter-pressure roller supports this phase with a calibrated response:
- Controlled elasticity: the double layer distributes pressure uniformly against the metal roller, promoting a consistent satin impression across the entire width of the film and tissue
- Adaptability to compounds and dimensional versions: the availability of multiple hardness values and dimensional formats allows the plastic response to be calibrated according to the thickness and type of film and tissue
- Preservation of product integrity: a well-balanced plastic response prevents tearing, thinning, or localized defects, maintaining the quality of the embossed effect throughout the entire production batch.
Thanks to the double-layer compound developed and offered by A.Piovan, with selectable hardness from 45 to 60 ShA, this counter-pressure roller ensures the right balance between temperature resistance and hot plastic response, guaranteeing a consistently high-quality embossed effect across all dimensional versions of plastic film and tissue processed.
