SECTION 1 ROLLER PRODUCTION INFORMATIONROLLER PRODUCTION INFORMATION 1. ROLLER PRODUCTION INFORMATION 1.1. Roller production technologies There are two classic methods for roller covering used by the traditional companies. 1.1.1 Classical system roller manufacturing methods The rubber is formed into a plate via calendering system and then rolled over roller mandrel. The other classic method is to wrap the rubber in long strips on to the rollerGES a 1.1.2. Roller production with “Extrusion Technology” In extrusion technology, extruder applies a homogeneous mixture process to the rubber compound fed from the feeder unit by the temperature controlled grooved mandrel and then process it through a 3 staged filtration system The rubber is then spiraled on the roller on the “crosshead” unit completely hand free and without any folding overs. The air within the rubber is sucked out via a vacuum system. All the micro foreign substances and residues are separated via 3 staged filters all with different dimensioned pores. a.’ Roller Metal Core to be Covered Rubber Feed os Finished Roller Temperature Controlled Grooved Barre! 3 Staged Filtration System ed The foreign structures and residues separated via filtrationGree RIN smooth and even surface is an important factor for achieving high printing quality. The risk of air bubbles is minimized by application of vacuum system, Dentures don't form during printing process, As a complete and non folding covering system is applied, metal-rubber adhesion problems do not occur, Rubber is filtered by 3 staged filtration system. This enables a smooth and even surface on the roller. The homogeneity and mixture quality of the compound increases as a result of the high pressure applied during the extrusion system, Thus, maximum performance is achieved from the roller. As the manufacturing of the rollers vary according to the mandrel diameters, manufacturing process with extrusion method is more costly compared to classical systems 1.1.3. Variation of Usage areas of the roller manufactured by classical systems and extrusion system The frequent problems encountered with the rollers manufactured with classical systems and the reasons for these problems, 1. Through vacuuming, the risk of remaining air-bubbles in the rubber mass is minimized.GOES a 2. Due to hand contact , the adhesiveness of the rubber onto the roller decreases. As a result the rubbers on the edges do not stick on to the roller completely or rubber slides of the metal 3. Due to the foreign substances within the rubber, a non even and a rough surface forms as filtration is not applied extru: What are the advantages of printing rollers manufactured technology? 1. Through vacuuming, the risk of remaining air-bubbles in the rubber mass is minimized. 2. As non folding and non attachment system is applied, the problem in metal-rubber adhesion is eliminated 3. Rubber is put through a 3 stage filter system and this enables to remove all the foreign substances and therefore provides a smooth surface 4. The homogeneity and mixture quality are increased and homogenous performance on all surfaces are achieved as a result of the high pressure applied during the extrusion system 5. As the manufacturing of the rollers vary according to the mandrel diameters, manufacturing process with extrusion method is more costly compared to classical systems. But its advantages and longer life span makes up for these extra costsOE ea 1.2 Our main principle with regard to our manufacture process We believe that our principle value with regard to manufacturing process differentiates Asteks from other manufacturers. Application of the combination of four principle values and provision of its continuity is carefully applied and guaranteed. 1.2.1 Application of new technology The extrusion technology explained in the above section is and can only be applied by a few number of companies in the world. Despite its costiiness due to manufacturing process, engineering know how, high investment value and difficulty in application, extrusion system is preferred to its positive effect on rollers usage life, increased productivity and other obvious advantages 1.2.2 Quality of Raw Material Long term contracts have to be made with the certified raw material suppliers in order to achieve continuity in the quality of raw material to be used. A rubber mixture consists of 14-15 various raw materials. The standardization of raw matetial can better be realised bearing in mind that there are hundreds of raw material suppliers, supplying thousands of products All the raw materials are put through tests in line with ISO 9001:2000 prior to their application in order to achieve continuity of the standards The rubber mixtures are produced within our factory and ready made rubber compounds are not purchased. This enables the usage of freshly produced mixtures and prevents the problems to be faced due to usage of stale mixtures.RE ea 1.2.3. Human resources The choice of raw material, mixture rates and sequences and their harmony are important for achieving the required rubber formulation Therefore professionals with adequate education and experience background are required ‘As Asteks, one of our major principles is to have relevant human resources. Our team consists of 9 engineers, 20 technicians and 150 workers whose main aim to provide the right solutions to our customer's requirements 1.2.4 User evaluations, research and development Development of a new type of rubber mixture is a very time consuming study as it requires not only laboratory work but also a continuous observation of the materials performance in the sector it is used. User evaluations and research development studies has to be catried out in coordination over a long period of time. The effect of print types, machinery types, and paper types used during printing with various rollers have to be observed The user data obtained from our customers are passed onto our manufacturing and research & development departments and the studies and manufacturing process are designed according to customer requirements.ROLLER PRODUCTION INFORMATION Flow Chart for Printing Rollers Collection of rollers from the customer and confirmation of the ., Roller Covering Info Form* by the customer Ww Arrival of the rollers at the factory Ww ‘Counting of the rollers, dimension control and marking of the charge numbers on the rollers Ww Mechanical control of the rollers, mandrels and deciding) ifn condition, repair or new mandrel placement needed Ww Dimension and number of rollers are - passed to the marketing department Ww Informing the production and Information flow planning department regarding > the order Quality Control) Unacceptable A Quality control results Quality check confirmation’ Packaging and labelling Ww Information flow to 4 > Information flow to quality the marketing Ww management management Ai Submission of the roller to the customerROLLER PRODUCTION INFORMATION 1.4, Measurement of the Rollers Grade The grade (hardness) for rubber materials is measured by shore and the measuring device is named as shore meter. The hardness grade of the rubber is the value read on the shore meter within the first 5 seconds of the measurement that is made by applying of 1 kg of force on 5mm thick rubber. The measurements made by hand are not so reliable as the 1kg pressure to be applied by hand varies from person to person therefore cannot be accurate. The tolerance for the measurements is = 3 degrees according to DIN norms. 1.5. Measurement of rollers surface profile and its importance Roller surface view under electron microscope The surface roughness of the roller that can be observed under electron microscope plays an important role for water and ink transfer. The surface profile is measured by “Ra”. The ideal surface properties are defined based on the usage and application areas. To correctly measure the Ra value, it is necessary to wait until the roller cools down. After that 3 diameter measurements from different angles will be taken and the average of them will be calculated.ROLLER PRODUCTION INFORMATION 1.6. Roller dimensioning method Mandrel's Diameter (1) Required outer diameter of the roller (2) Length of the roller (3) Usage area (4) Machinery model and type (6) ee 2 Mandrel’s Diameter: The diameter is measured with a caliper and identified in mm. Required outer diameter of the roller: To be defined in terms of mm and shall be confirmed with the values given in machinery catalogues Length of the roller: The rubber covered part of the roller is measured in mm. The special requirements to be applied for the rollers’ ends shall be defined separately. Usage area: The position of the roller /sequence in operation shall be identified. The rollers to be manufactured according to their usage areas will assure longer life spans and better performances. Machinery model and type: The machinery model /type /manufacturer shall be stated such as Roland 700 (R700)