Solutions

for the

Converting Industry

A

Menges Roller Company has been serving the converting industry with innovative products and high-value services for over 40 years. This experience gives us the knowledge, skills and insight needed to provide real solutions to real challenges.

Menges Roller provides roller products and services that help you run faster, waste less and produce better products.

Converting Rollers & Services

One of our specialties is large process rollers.

Over 18 feet long, this one was sent to us for

refurbishing. We recovered with a premium

elastomer and repaired the journal shafts.

Application Engineered for Your Unique Needs The Only Industrial Roller Source You’ll Ever Need

Menges Makes All Types of Rollers Used in Converting

Process Rolls of All Types & Sizes

Small to Large Rubber Covered Rolls Web Spreader Rolls Feed Rolls

Idler Rolls

Layon Rolls for Adhesives & Coatings

Chill & Heat Transfer Rolls

Menges Rollers are a one-step solution to common

web handling issues. A variety of highly-effective

patterns are available, including herringbone,

diamond, fluted serrated and many others.

Unlike many roller fabricators, Menges has in-house

rollcovering capabilities. Our body of knowledge in

rollcoverings spans 40 years, so we know what

compound to recommend, how to apply it, and

how to groove it for maximum efficiency.

Important Repair Services for the Converting Industry

Rollcover Stripping & Recovering with any elastomer

Core Repair: Regrinding & Rebuffing

Chrome Replating & Finishing (to mirror/any Ra value)

Acid Flushing of Heat-Transfer/Chill Rollers

Repairing Internal Parts on Heat-Transfer/Chill Rollers

Journal Repair & Replacement

Two-Plane Dynamic & Static Roller Balancing

Grooving & Parabolic Crowning

Elastomer Consulting: Compounding & Testing Services

Rollcovers – Mastering Chemical, Thermal & Physical Properties

Menges Roller is a market leader in elastomer development and use. In addition to covering with any formula on the market today, we can blend custom compounds based on your specific requirements.

Available Rollcovering Compounds (partial list)

Natural Rubber

Hypalon

Silicon & EPDM Silicon Blends

EPPM

Nitrile (NBR / BUNA)

Neoprene

Anti-Static Blends

Hypalon Blend for Corona Treatment uses

Viton (Fluoroelastomer)

FDA Approved coverings

Thermal Plastic Urethane / Tiger Max

Cast Film

Packaging

Laminating

Coating

Extrusion

Non-Wovens

Serving Every Converting Industry Sector

Core Manufacturing - The Right Design for Your Application:

We provide new replacement cores via reverse-engineering your existing roller or from a drawing or schematic. Menges manufactures thousands of roll cores for OEM and after-market installations to be rubber covered or chrome plated. Our fabrication facility is exceptionally large, as are many of our machines, giving us the capacity to produce precision roller cores as long as 30 feet and up to 48 inches.in diameter.

Hardshell Finish & Plating Options

Chrome (polished to mirror or any Ra value)

Nickel Plated

Standard Lathe Finish

Grit/Shot Blasted Matte Finish

Machine-Cut Grooving

Tempered & Case-Hardened

Thermal Spray (abrasion & corrosion-resistant coating)

Roller Core Materials

High-Grade Carbon Steels

Aluminum & Aluminum Alloys

Carbon Fiber

Here with Matt Menges, each of these rollers is over 26 feet long.

We made double-plated journal sets capable of withstanding

incredible loads. To ensure peak performance on the job, we

dynamically balanced these super-sized rolls. Few suppliers

can build large rolls to such exacting specifications.

Precision-made liveshaft roller cores like these represent one of

our key offerings. We manufacture cores up to 30 feet long and

48 inches in diameter - a capability beyond most competitors.

With one of the most complete fabrication facilities in the

industry, Menges constructs all roller types: liveshaft,

deadshaft, and recessed bore formats, as seen above.

Extending Roller Life - Repair & Refurbishing Services

Journal Repair & Replacement

Regrinding & Re-Plating

Diameter Modification for Journals

Bearing Race Resurfacing

This heat transfer roller

- which serves on a

laminating line in a

flexible packaging

operation -

is being cylindrically

ground in-house and

will be re-plated with

mirror-finish chrome.

Advanced CAD

technology is

employed to

model

performance

dynamics and

generate

accurate prints.

Grooving & Serration Services for Converters - Reduce Waste, Increase Uptime, Run Smoother

Menges Roller offers a multitude of grooving and serration options, each designed to solve particular problems in the handling and processing of paper, foil and film. These rollcovering & grooving options can be applied to new or refurbished rollers.

Combined with the proper rollcovering compound, our precision-machined patterns cause substrates to feed smooth and flat. Our rolls help converters take control of viscous liquids and gelatinous adhesives, making them layon even and thin.

So take back control of your web. Speak to your Menges sales engineer today and finally solve those persistent problems.

In addition to rubber web spreaders, we

make aluminum herringbone web spreaders.

Special Options for Special Needs Acid & Alkali Resistant Compounds

Anti-Static Treatments

FDA Approved Applications

We custom-made these roller cores, covered

them with our Tiger Max thermal plastic

urethane, and then grooved each to perform

a specific material handling task.

These are for a flexible packaging customer.

We made the shafts, covered in Hypalon 65

(durometer Shore A) and grooved with our

Menges herringbone pattern.

Rollcovering for Results Faster Linespeeds

Scrap & Waste Reduction

Less Down-Time

Improved Process & Product Quality

Groove and serration work is always enhanced by the proper rollcovering compound. Menges started out as a rollcovering house, so we understand the chemical, thermal and physical characteristics of today’s elastomers.

We can cover your roller with any compound on the market today - rubber, silicon or urethane-based. Menges can also formulate custom compounds to meet specific requirements.

MENGES WEB SPREADER: This roll is ideal for smoothing wrinkles in thin-gauge materials such as foils, paper and film. Available in durometers from 25 to 90 Shore A, it’s tough enough for continuously running lines. Web spreaders usually run in idler positions, but they can be placed in almost any problem area. We can convert your existing roller to a web spreader or manufacture a new roller with this very effective pattern.

MENGES HERRINGBONE Used as not only a web spreader, but also as a feed roller, a Menges herringbone roller is ideal for boardly products such as SPS board, corrugated and other hard to feed/hard to align products. Paired with one of our proprietary rubber compounds – it will stand up to your harshest “in-feed” applications.

DIAMOND SERRATION Used for many applications, but most often in flexible packaging, this groove format performs superbly and is used by many OEMs as a layon roller. It has excellent channeling abilities to move air or liquid away from substrates.

FLUTED ROLLER SERRATIONS This roller is used in applications where lateral serrations can be beneficial, such as spreading thicker adhesives and handling rigid or weighty stock. Your Menges sales engineer can advise you on which groove pattern would be most effective in solving your particular material handling problem.

CIRCUMFRENTIAL SERRATIONS This roller is very effective at aligning substrates for in-feed operations. It allows materials to pass between rollers without being crushed. Menges custom-serrated rollers can be used in pairs and may be strung to eliminate wrapping-up of substrates where webs change direction.

Negative Effects of Non-Crowned Rollers are Easy to See:

Uneven distribution of adhesives between laminate layers

Coatings are spread unevenly

Poor web alignment

Downtime is increased

Rollcoverings wear-out quicker

Machines have a shorter lifespan All these factors negatively effect product quality and your shop’s reputation...but Menges Roller can help!

Roll Crowning / Profiling - For Uniform Roller Contact, Contact Menges Roller

For rollers used in nip and squeegee applications, crowning can be the single most important factor in determining performance.

Crowning counters the effects of roller deflection, which is basically a slight bending in the rollers. In a typical nip system, roller ends tend to make tight contact and squeeze the web material tightly, while the middle section will have airspace or play.

Figure 1 demonstrates this clearly.

Figure 1 - Non-Crowned Rollers in Nipping System In a nipping or squeegee system, if rollers are not crowned,

converters will see uneven contact and pressure, resulting

in poor laminating and decreased product quality.

Menges to the Rescue:

Menges Roller utilizes specialized software tied to advanced machinery to creates the perfect parabolic profile. Specifying a roller’s crown must done cautiously - a few mils (.001”) can make a huge difference - and Menges Roller is uniquely qualified to handle this complex task for converters.

To calculated the proper Cosine Curve, or diametric crown deficiency, we take a number of factors into consideration, including operating load, desired nip pressure, roller specifications and other relevant throughputs.

Sometimes called “profiling,” crowning is a service few fabricators can fulfill and seldom with our degree of accuracy.

Testing Your Roller’s Profile - Nip Impression Paper

At Menges Roller, rollers are our lifeblood and passion, which is why we’ve developed products to enhance and measure the performance of rollers for the converting industry. Our Nip Impression Paper is a breakthrough product that allows operators to measure the “even-ness” of nip pressure.

This special paper is inserted into your nipping crimp, where visible impressions are made to show areas of proper nip pres-sure or where contact is poor, indicating a need for profiling services. Available only from your Menges Roller Sales Engineer, this important product allows you to determine if rolls need to be crowned, reverse crowned, and in which portion of the roll.

Figure 2 - A Properly Crowned Rollers from Menges Although this illustration is exaggerated a bit to make the

point, a crowned roller will have a parabolic arch, with the

angle and size being determined by a range of factors

Balanced is Better

Unbalanced rollers can cause damage to bearings and machinery. In some cases, poorly-balanced rolls can damage substrate stock.

Menges has invested heavily in sophisticated computer-interfaced alignment and balancing machines. Using this technology, every new roller is static and dynamically balanced, ensuring smooth and true functionality over long-term use.

We do offer our balancing services as an ala-carte service, and we are happy to balance your existing rolls. You’ll see a decrease in vibrations, longer component life and a smoother flow of materials.

Application Engineered for Your Unique Needs Menges Roller Company

www.mengesroller.com 260 Industrial Drive Wauconda, IL 60084

Phone: 847-487-8877 Fax: 847-487-8897

Advanced Roller Technology for Converters - Chill & Heat-Transfer Rollers

Menges is at the leading edge of advanced heating and cooling technology for rollers used in cast film, extrusion, laminating and other converting-related sectors. Sometimes called “chill rolls” or “heat transfer rolls,” we design, test and fabricate very

specialized double-walled thermal rollers. Menges Thermal Rollers maintain constant temperatures to within +/- 1 F.

Heated rolls are often used in gluing or laminating lines: the roller’s heat greatly enhances the adhesive properties of glues.

Heating materials quickly and evenly, our heat-transfer rolls are typically capable of maintaining temperatures up to 400 F.

Chill rolls are primarily used to quickly cool previously-heated materials, saving time vs. waiting for materials to naturally cool. One key application is making materials “instantly rigid,” essentially decreasing set times after partial melts or extrusion feeds.

Although specs, materials and finishes can vary greatly, thermal rollers are typically split into three wide categories:

Double-Shell Duo-Flow Configuration:

The roller core contains a siphon tube and rotary union, through which

the heating/cooling liquid flows both in and out. This type of thermal

roller offers excellent temperature control, while saving a bit of space

on the production floor.

Double-Shell Mono-Flow Configuration:

This design allows the heating/cooling liquid to flow in one end and

out the other end of the roller. The mono-flow configuration provides

outstanding temperature control and our expertise in fabricating these

rollers is unsurpassed.

Single-Shell Configuration:

Also known as the “can” design, this economic thermal roller meets

basic temperature control needs and is used in non-critical heating

and cooling applications. We can engineer and manufacture these

rollers to fit your exact size, finish and core specifications.

Menges Roller fabricated this large heat-transfer roller for

a major package producer. With a double-shell mono-flow

spiral-baffle design and a mirror-pocket finish, the roller

face is over 9 feet long and 30 inches in diameter.

Maintain Thermal Roll Performance - Acid Flushing

Existing chill & heat-transfer rollers that are not performing optimally may be

clogged with scaling or mineral deposits resulting from unbalanced water or

chemicals. Menges offers a unique acid flushing service that breaks down and

flushes deposits of calcium, rust and congealed chemicals. Customers see

immediate improvements in thermal transfer performance. This also allows

engineers to dial back flow rates; you save energy and increase the lifespan of

rollers, pumps and connected equipment. Ask your Sales Engineer about our

uniquely effective acid flushing services for your thermal roller.

This heat transfer roller performed for many

years without acid flushing. Had the service

been done, it could have lived a longer life.