SEMINAR

ON
CALENDERING

PRESENTED BY
MARIA IMMANUEL RICHARD L
II ND SEM M.Tech TOOL ENGINEERING
R V COLLEGE OF ENGINEERING
 Calendering
 In the calendering process melted
plastic is passed through heated rolls to
form a sheet, and continues down a
series of rollers with gaps of decreasing
size until the required thickness is
achieved. Afterwards the film is cooled
on a chill roller.
http://www.plastiquarian.com/manufact.htm
 The equipment for calendering cost
more than the equipment for extrusion.
However, the process involves far less
cleaning than the extruder, which must
be flushed and cleaned post use.
The Machine
Typical Calender Line
Calender Roll Arrangements

I F

Z
 Calendering Sheet Defects

 Dimensional Non-uniformities
 Thickness variations in the sheets due to roll bending with large separation forces.
Compensated with crowned rolls – larger diameter in center than at ends.
 Structural Anomalies
 Particulate and crystalline structure changes under the influence of high temperature
and stress
 Mattness
 Micro-irregularity or loss of surface gloss on the surface not in contact with the roll
when leaving the calender gap. Onsets at a wall shear stress value of 5x10 8 Pa.
 V-shapes
 Surface thickness variations with vertex of v-shape at center of sheet. Due to
undulating motions in the melt bank from the center to edges.
 Air Bubbles
 Captured in the melt bank. Can be prevented from passing through the calender rolls
through high pressure.
 Uses

 Major plastic material is PVC

 Also produced are:
 Wall coverings
 Upholstery fabrics
 Reservoir linings
 Agricultural mulching
materials
 Rubber sheet
 Rubber
 Made by a combination of extrusion and
calendering
 “roller die process”
 Better quality products than single process
 Coating and Impregnating Fabrics

 Industrial process
used to produce:
 Car tires
 Conveyer belts
 Inflatable rafts
 Waterproof cloth
tents
 Rain coats
 Limitations
 Thickness
 Generate film or sheet with a uniform thickness
distribution
 Precise dimensions of the rolls
 Cost
 Installation requires large capital investment
 Extruder is fraction of cost of calender
 Superior for product production due to high
quality and volume capabilities