Case Study
Fenner Precision rollers extend life and improve performance in filter rod manufacturing.
Challenge
Existing nitrile rubber tow blooming rollers are a weak link in the filter rod production line, causing frequent downtime. Rubber tow rollers can build up static electricity, causing roll wraps and the associated lost production. In addition, they wear quickly, often after only 1,000 run hours. This short run life causes wasted tow, increased downtime, and increased replacement costs. A leading tow manufacturer came to Fenner with these concerns and requested assistance in developing new rollers that would work in conjunction with their acetate tow for better performance and profitability.
Approach
Fenner Precision’s R&D department reviewed the issues with the existing rubber rollers with an eye to both increasing roller life and eliminating the causes of down-time. A new polyurethane composition was developed and tested specifically for the filter rod manufacturing industry.
Results
Fenner Precision’s polyurethane rollers, using our Winthane®D2820 formulation, provides superior wear resistance, resulting in longer roller life and lower replacement costs. Fenner Precision’s rollers offer several advantages over the old format rubber rollers, including UV and solvent resistance, a conductive formulation to reduce static and tow wraps, and a liquid based process to ensure homogeneous material throughout the roller. Fenner tow blooming rollers are available in all industry standard sizes and offer easy drop in replacement. As an extra advantage, there is no break-in period required unlike rubber rollers. Manufacturers who have transitioned to these rollers have seen roller life of 4,500 hours or more, increasing the profitability of their production line and the quality of their product.
