Dessa-NV meets the economic crisis with the installation of an extruder for the production of rubber rollers
up to 7m long, 1.5m in diameter and weighing up to 10t. Supplier: "Italmatic (Italy).
In 2009, we decided to develop our own production facilities to fully meet the needs of paper companies in Ukraine and neighbouring countries. The initial parameters of the project were the availability of sufficient space for all technological operations and storage, stable quality with minimisation of the negative impact of the human factor, and modern productive equipment to reduce the time required to complete the work. For this purpose, a 1000 sq m shop No. 3 was built, and two DIP-600 lathes were purchased in addition to the existing two, one of which is equipped with a CNC grinding head for boring and spiral tapping. An additional 8-metre shot blasting chamber was also installed.
The most important thing was to ensure fast and high-quality application of rubber compounds, which determines the strength of the coating's connection to the metal roller core at high loads from 40 to 300 kg/cm and the absence of air bubbles in the coating structure. Among the equipment suppliers from Germany, Italy and India, the company chose Italmatic, an Italian company that, in addition to its own production of rubber shafts, manufactures a full range of rubber equipment.
The company's extruder is reliable and simple, combined with full automation and control of operations. The standard parameters of the extruder offered by the manufacturer were increased by order - up to 7 m in length, 1.5 m in diameter, and 10 tonnes in weight, i.e. brought into line with the specified technical parameters of the new shop. The extruder was installed in-house, and the launch under the supervision of the supplier's representatives ironically fell on 1 April (April Fools' Day), which the team believes is a good sign.
The first days of work with the new equipment proved that we had made the right choice and met our expectations. Since April 2009, all rollers from 2 to 7 metres in length have been rubberised in the new shop on the new machine.
Additionally, the purchased mixing machine allows to produce rubber compounds as a semi-finished product and finalise the compounds immediately before use, which allowed Dessa-NV to reduce the cost of production and, accordingly, to revise the cost of work downwards, which is important, especially in the current economic situation.
In the near future, the company will launch a dynamic balancing system with a speed of up to 2,000 m/min, and all paper rolls will undergo final balancing at the customer's request. New rolls will be balanced on a mandatory basis. Previously, we had to have the rolls balanced by third-party organisations or leave this operation to the customer to perform on their own.
Today, the only thing we cannot offer our customers is perforation of press rolls, which is why Ukrainian companies are forced to order perforated rolls abroad (Slovenia and Poland). Some companies order the application of a new rubber coating from us, and perform the perforation manually. However, Dessa's management is already working to eliminate this drawback.
Fully computerised process control, wide capabilities of the new equipment combined with the use of more than 200 types of rubber compounds from Germany, England and Italy allow us to meet the highest customer requirements for the quality and performance parameters of rollers for any purpose of paper-making equipment.
