3600/400 Calender Machine

1.Name and Model

It is called the 3600/400 calender machine. The "3600" clearly represents that the maximum web width of the paper that can be processed is 3600 mm, and this parameter determines the range of paper sizes it can accommodate. For large-scale papermaking production lines, an appropriate web width can improve production efficiency and paper consistency. The "400" precisely indicates that the diameter of the calendering rolls is 400 mm, and this size has a significant impact on the calendering effect and pressure distribution.

This calender machine plays a crucial role in the papermaking industry and is one of the indispensable equipment in the paper production process for enhancing the quality and performance of the paper.

2.Usage

It is mainly used for the calendering treatment of paper during the papermaking process. Through calendering, the surface properties of the paper can be significantly improved, making the surface smoother and with higher gloss, thereby enhancing the printability and appearance quality of the paper. Simultaneously, the calendering treatment can also enhance the physical properties of the paper, such as increasing the tightness, thickness uniformity, and tensile strength of the paper, enabling it to perform better in subsequent processing and usage.

1.Calendering Rolls

Usually composed of multiple metal rolls, the material is high-strength alloy steel or cast iron. These materials have excellent hardness, wear resistance, and high-temperature resistance, and can maintain a stable shape and surface quality during long-term operation.

The surface of the calendering rolls undergoes meticulous processing, such as chrome plating, grinding, or polishing, to ensure an extremely high surface finish and flatness. This is crucial for achieving a uniform calendering effect and avoiding defects or uneven gloss on the paper surface.

The number and arrangement of the calendering rolls can vary depending on the design of the calender machine and production requirements. Common combinations include hard-hard roll combinations and hard-soft roll combinations, each with its specific calendering effect and application range.

2.Pressurizing Device

It is used to apply pressure to the calendering rolls. Common methods include hydraulic pressurization and mechanical pressurization. The hydraulic pressurization system precisely regulates the pressure size through hydraulic cylinders and control valves, and it has the advantages of fast response speed and high pressure control accuracy. Mechanical pressurization typically uses screw mechanisms or eccentric wheel mechanisms. The structure is relatively simple, but the flexibility of pressure adjustment may be slightly inferior.

The pressurizing device can flexibly adjust the pressure between the calendering rolls according to different paper types, thicknesses, and calendering requirements. An appropriate pressure can ensure that the paper is adequately compressed and rubbed during the calendering process to achieve the desired surface smoothness and gloss.

3.Transmission System

It includes components such as motors, reducers, and couplings. The motor provides the power source, and usually, a high-power AC motor or DC motor with good speed regulation performance is selected to meet the requirements of different production speeds.

The reducer converts the high speed of the motor into the appropriate speed required by the calendering rolls and provides sufficient torque output. The coupling is used to connect the motor and the reducer, as well as the reducer and the shaft of the calendering rolls, to ensure smooth and reliable power transmission.

The stability and speed regulation performance of the transmission system have a direct impact on the working efficiency and calendering quality of the calender machine. Precise speed control enables the calender machine to adapt to changes in different paper varieties and process conditions, ensuring consistent calendering effects.

4.Heating Device

Some calender machines are equipped with heating devices, such as hot oil circulation systems or electric heating elements. The heating device can increase the surface temperature of the calendering rolls, helping to soften the paper fibers and enhance the calendering effect, especially for papers that require higher gloss and surface smoothness.

The heating temperature can be precisely controlled according to the characteristics of the paper and calendering requirements to avoid excessive heating that could lead to a decrease in paper quality or safety incidents.

5.Lubrication System

To ensure the normal operation of the calendering rolls and other moving parts and reduce wear and friction, the calender machine is equipped with a comprehensive lubrication system. The lubrication system typically includes components such as oil pumps, oil pipes, filters, and oil distributors.

The type of lubricating oil and the lubrication cycle are selected and determined based on the operating conditions of the equipment and the manufacturer's recommendations. Regular lubrication maintenance is crucial for extending the service life of the equipment and ensuring the stable operation of the calender machine.

6.Control System

It adopts an advanced automated control system, such as a PLC controller and a touchscreen operation interface. Operators can conveniently set and adjust the operating parameters of the calender machine, such as machine speed, pressure, and temperature, and monitor the operating status and various process parameters of the equipment in real-time through the control system.

The control system also has fault diagnosis and alarm functions, which can promptly detect and handle abnormal situations during the operation of the equipment, improving the reliability and safety of the equipment.

7.Frame and Protective Devices

A sturdy frame is used to support and fix each component of the calender machine, ensuring the stability and safety of the equipment during operation. The frame is usually welded from thick steel structures and has sufficient strength and rigidity.

Protective devices include safety covers, protective doors, and emergency stop buttons, which are used to protect the personal safety of operators and prevent accidental incidents during the operation of the equipment.

1.Paper Entry

Paper that has undergone previous treatments, such as drying and sizing processes, enters the calendering area of the calender machine at a specific speed and tension.

2.Calendering Process

The paper is subjected to pressure and friction between the calendering rolls. The surface finish and pressure distribution of the calendering rolls cause the fibers on the paper surface to be rearranged and compacted, thereby eliminating surface roughness and non-uniformity.

Simultaneously, depending on the configuration of the calender machine, if there is a heating device, the paper fibers will further soften at a certain temperature, enhancing the calendering effect.

3.Paper Output

The paper that has undergone the calendering treatment is output from the calender machine, and its surface and physical properties are significantly improved to meet the requirements of subsequent processing and usage.

1.Efficient Calendering：It can perform high-quality calendering treatment on a large amount of paper in a short period, improving production efficiency.

2.Stable Calendering Quality：With precise pressure control, temperature adjustment, and good roll surface quality, it ensures high consistency in the calendering effect of each paper and reduces quality fluctuations.

3.Strong Adaptability：It can adapt to different types, thicknesses, and grammages of paper and meet the calendering requirements of various papers by adjusting parameters.

4.Convenient Operation：The modern control system makes the operation simple and intuitive, reducing the training time and work intensity of the operators.

5.Easy Maintenance：The reasonable structural design and easily detachable components facilitate daily maintenance and troubleshooting, reducing equipment downtime.

1.Printing Paper：Such as paper for books and magazines, the calendering improves the printing quality and graphic clarity of the paper.

2.Packaging Paper：Used for making packaging materials such as cartons and paper bags, the calendered paper has better appearance and strength.

3.Specialty Paper：Such as art paper and security paper, in fields with special requirements for the surface and physical properties of the paper.

1.Regular Inspections：Include the surface condition and wear degree of the calendering rolls, the working performance of the pressurizing device, and the lubrication condition of the transmission system.

2.Cleaning and Maintenance：Promptly clean the dust, paper scraps, and oil stains on the equipment surface to keep the equipment clean. Regularly replace the lubricating oil and filters to ensure the normal operation of the lubrication system.

3.Component Replacement：For severely worn or damaged components, such as calendering rolls and bearings, replace them promptly to ensure the performance and accuracy of the equipment.

4.Training and Operating Specifications：Provide regular training to the operators to ensure they are familiar with the operation and maintenance procedures of the equipment and avoid equipment failures and damages caused by incorrect operations.

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