Double E Company - Carbon Fiber Rollers

Benefits of carbon fiber idler rolls ~ Coatings for carbon fiber rollers

Carbon fiber idler rollers (composite rollers) are designed for reduced weight and high critical speed.
Lightweight, low-inertia idler rollers allow faster web speeds, reduce vibration, decrease waste, and improve product quality.

Carbon Fiber Roller

Idler Rollers ~ Transducer Rollers ~ Accumulator Rollers ~ Guide Rollers ~ Contact Rollers ~ Nip Rollers ~ Dancer Rollers ~ Lay On Rollers ~ Calender Rollers ~ Reel Spools ~ Roll Cores

To see a short movie about Light-Speed composite rollers, please click below.

Please click here if you would like a quotation on low-inertia carbon fiber rollers

WHY CARBON FIBER
ROLLERS / ROLLS?
Carbon fiber rollers have low rotational inertia, high stiffness, a high stiffness to density ratio, low mass, and low momentum.

Feature	Advantage	Benefit
Low Rotational Inertia (Reduced mass moment of inertia by up to 80%)	Rollers spin at line speed.	Far less web scratching. Reduced roller wear. Dissipates static electricity.
	Quicker response to changes in line speed.	Fewer web breaks. Far less start-up waste. Less web stretch. Less web wrap-up in the event of a web break. Extended idler roller life and reduced coating thickness.
	Less horsepower and/or fewer motors required.	Lower energy consumption.
High Stiffness (High Modulus)	Less deflection.	Less web wrinkling. Longer bearing life.
High Specific Modulus (High Stiffness to Density Ratio)	Faster line speeds with less vibration. (Higher critical speed).	More throughput and better product quality.
High Specific Modulus (High Stiffness to Density Ratio)	Less self-loaded deflection.	Less web wrinkling across wider spans.
Low Mass	Super lightweight.	Easier and safer handling.
Low Mass	Less bearing wear.	Longer bearing life.
Low Momentum	More accurate transducer measurements.	More precise tension control.
	Less lay-on roller bounce.	Higher quality wound rolls with less air entrainment.
	Quicker dancer and accumulator roller response.	Better dancer and festoon performance with consistent tension control and less web stretch.

The importance of idler rollers (idler rolls) with low rotational inertia
Lightweight, high-stiffness carbon fiber rollers exhibit lower inertia to acceleration and deceleration (rotational or translational), and can run at higher speeds. Composite rollers reduce waste while increasing productivity and efficiency.

Carbon fiber idler rollers provide better performance than traditional steel or aluminum rollers, particularly when wide web widths, heavy loads, and faster speeds are necessary. Consider this example where a 164 inch steel roller with an 11.25 inch O.D. was replaced with a carbon fiber roller with the same dimensions:

	Weight	Rotational Inertia
Existing Steel Roller	1000 lbs.	34,330 lb.-in.2
Light-Speed Carbon Fiber Roller	220 lbs.	4200 lb.-in.2

ROLLER / ROLL COATINGS
Carbon fiber rollers can be coated with most of the same materials that metal rollers can be coated with. Many standard coatings are available (shown below), but please ask if you want a specific type of coating.

Dura-Stat: STANDARD COATING. Wear resistant, conductive polyurethane which works to prevent buildup of static charge on rollers. Suits most idler roll applications. Economical, resistant to most chemicals and abrasion, repairable, and replaceable. Black in color with an appealing satin finish. Surface Finish: 32 µin Ra (0.8 µm Ra).

Dura-Clear: Durable clear-coat polyester urethane. Non-conductive. Surface Finish: 32 µin Ra (0.8 µm Ra).

Dura-Clear Gloss: Polished clear polyurethane, non-conductive. Similar to Dura-Clear, but has a mirror finish surface that is friendly to sensitive web materials such as very thin films or very thin film/foil laminates. Surface Finish: 4 µin Ra (0.1 µm Ra).

915D: Nickel Chromium Thermal Spray with Release offers wear resistance, traction, and release all in one coating. This coating has successfully served in many applications with adhesive coated web materials. The silicone release agent in this coating prevents even aggressive adhesives from sticking. Surface Finish: 215 µin Ra (5.5 µm Ra); Hardness Rc 58; Color: Silver-Gray.

LC4: Chromium Oxide Plasma Spray offers a rock hard, ceramic surface that has extreme resistance to abrasion and chemical attack. This coating can be polished to approximately 10 µin Ra (0.3 µm Ra) when sensitive web materials are to be run. Standard Surface Finish: 80 µin Ra (2 µm Ra); Hardness Rc 72; Color: Dark Green-Black.

Please click here if you would like a quotation on low-drag carbon fiber idler rollers.