Lay-on rollers

Lay-on rollers made of CFRP

INOMETA carbon fiber reinforced polymer (CFRP) lay-on rollers offer a wide range of applications in various industries thanks to their exceptional properties. These rollers, characterized by their high stiffness, low weight, and excellent damping properties, are specifically designed to meet the demands of modern production processes.
They are indispensable components in the winding process of many industrial applications, controlling the winding process, monitoring material tension, and ensuring even winding. Customized manufacturing allows them to be optimally adapted to the specific needs of each application, resulting in a significant increase in efficiency and quality.

Flexure-optimized and adjustable CFRP lay-on rollers – our lay-on rollers in practice

INOMETA CFRP lay-on rollers are flexible components that are crucial in many industrial processes thanks to their high precision, durability and adaptability. Whether in the film, paper, textile or packaging industry, lay-on rollers offer outstanding performance that helps to optimize production processes and improve product quality. Their customized production and the use of high-quality materials make them an ideal solution for demanding applications in various industries.
CFRP can be used to produce lay-on rollers with defined deformable roller bodies and special bending lines. There are two options: a lay-on roller that is precisely set to a working point or an active roller system that continuously adapts to the process.

The selection of the right lay-on roller depends on various factors, such as the material to be wound, the desired winding density, the surface quality of the material and the specific ambient conditions. The areas of application for our CFRP lay-on rollers include:

• Film industry
• Textile industry
• Packaging industry,
• Printing industry
• Metal processing
• Plastics processing
• Battery production

All benefits of INOMETA lay-on rollers at a glance

The adaptability of INOMETA lay-on rollers is demonstrated by the availability of different dimensions and designs, which enable optimum adaptation to the individual requirements of the respective application.

The advantages of INOMETA’s CFRP lay-on rollers include:

• High rigidity
• Low concentricity
• Optimum pressure distribution
• Low shrinkage behavior
• Excellent damping properties
• Smooth transportation of materials through production lines
• Available in various dimensions and designs
• Prevents blistering and creasing
• Protects sensitive materials
• Increases production quality through precise guidance
• Prevents material damage
• Increases process speed and efficiency
• Long service life
• Flexible use in individual applications

Lay-on rollers LDS

The lay-on roller is of crucial importance in the production of very wide bi-axially stretched film. It is pressed against the winding material to prevent air from getting between the material webs. Correct winding is an important parameter for the film production speed. The film wrap must be perfectly structured even at the highest machine speeds. Irregularities in cylinder shape, winding hardness or edge shape are not permitted. The main reason for these faults is that air is drawn in between the material layers of the wrap. The task of the lay-on roller is to prevent precisely this air intake.

Lay-on roller LDS – the passive system made of CFRP

The deflection has been significantly reduced for the low-deflection-system lay-on roller (LDS) made of CFRP. The LDS roller offers a special design of the CFRP roller body. The roller body is designed according to the principle of shifting the support points. In comparison, the maximum deflection of an LDS lay-on roller from INOMETA is around 90% less than with conventional lay-on rollers. 

Lay-on rollers ALDS

The lay-on roller is of crucial importance for the manufacturing of bi-axially stretched films with great material widths. It is pressed against the winding material to prevent air from entering between the material webs. With the ALDS (active low deflection system) you will be provided with the option to continuously influence the deflection of the lay-on roller during the winding process. 

ALDS lay-on roller – the active system made of CFRP

The active low-deflection system lay-on roller (ALDS roller) made of carbon fiber-reinforced plastic (CFRP) is an active lay-on roller that reacts independently to the machine parameters. The lay-on pressure line can be continuously adjusted during winding in order to adapt the lay-on pressure forces. The ALDS lay-on roller can be adjusted, for example, via an autonomous control system that is connected to the winding control system. The signal from the current winding pressure can be used to automatically adjust the roller shape in defined steps, thus ensuring optimum lay-on force between the roller and the winding. By constantly monitoring the process parameters and automatically readjusting them, the ALDS lay-on roller can react to changing operating conditions. If the tension or lay-on pressure changes, the lay-on pressure can be distributed differently. This means that the set pressure force can be distributed more towards the center or the edges of the winding as required.

Lay-on rollers in the winding process

Lay-on rollers are indispensable components in the winding process of many industrial applications in which materials such as paper, films, textiles or metal strips are wound onto rolls. These rollers play a central role by controlling the winding process, checking the material tension and ensuring uniform winding. Their flexible and efficient design contributes significantly to the optimization of industrial production processes.
The main tasks of lay-on rollers in the winding process can be divided into several areas. Firstly, precise guidance of the material is crucial. The lay-on roller guides the material to be wound precisely to the coil and ensures that it is wound evenly and without tension. This prevents undesirable effects such as wrinkling or material damage that could affect the quality of the end product.
Another important aspect is the generation of lay-on pressure. Our lay-on rollers press the material along the web guide with a defined pressure to ensure good adhesion and prevent slippage during the winding process. 
The winding density of the material can also be influenced by the lay-on roller. Adjusting the lay-on pressure makes it possible to vary the winding density. A higher winding density results in a more compact winding and can reduce material consumption, but must be carefully controlled to avoid excessive tension on the material.
In addition to guiding and pressure control, the lay-on roller can also be used for surface treatment of the material. For example, it can smooth or polish the material to achieve an even surface. In some special applications, lay-on rollers can also be used to apply adhesives or coatings, which further increases their functionality.