Rubber roller coating (also known as roll covering or lagging) is a critical process that determines roller performance and service life. Below is a simplified breakdown of the complete process.
1. Surface Preparation
The metal core is thoroughly cleaned and degreased to remove all contaminants.
Sandblasting creates a rough surface profile for optimal bonding.
2. Adhesive Application
A specialized primer and bonding agent are applied to the prepared surface.
This chemical layer ensures permanent adhesion between rubber and metal.
3. Rubber Application
Two main methods are used:
Extrusion – Rubber compound is wrapped around the core in sheet form.
Injection Molding – Liquid rubber is injected into a mold around the core.
4. Compression Molding
The wrapped or molded roller is placed in a press and subjected to controlled heat and pressure.
This step cures the rubber and bonds it tightly to the metal substrate.
5. Vulcanization (Curing)
The roller is heated in an autoclave or oven at temperatures typically between 140–170°C.
This cross-linking process gives the rubber its final mechanical properties – hardness, elasticity, and durability.
6. Finishing Operations
The coated roller is ground to precise dimensions and surface finish.
Polishing or texturing may be applied depending on the intended application.
7. Final Quality Control
Hardness testing ensures consistency with specifications.
Dimensional inspection confirms tolerances are met.
Visual inspection checks for surface defects such as blisters or voids.
Process Parameters That Affect Quality:
| Parameter | Impact |
|---|---|
| Surface preparation | Bond strength and longevity |
| Temperature control | Consistency of curing |
| Pressure during molding | Density and void prevention |
| Grinding accuracy | Running smoothness and performance |
Our coating facility is equipped with advanced autoclaves and precision grinding machines to deliver rollers that meet your exact specifications.
For questions about our coating capabilities or custom material formulations, please contact our technical team.
