Calender lines

for Rubber production THE STORY OF A SUCCESS

The story of a success FONDERIE ED OFFICINE MECCANICHE RODOLFO COMERIO: founded in 1878 under this company name by Rodolfo Comerio in ,The , story considered of ata that success time the Italian capital of textile industry, it started its business FONDERIE ED OFFICINE MECCANICHEexactlyFONDERIE with designing ED OFFICINE and manufacturing MECCANICHE CALENDERS FOR RUBBER calendersRODOLFO and textile COMERIO: padders and founded since then in 1878 the under Companythis company has come name a long by way. Rodolfo Comerio in Busto In Arsizio,the early Italy, 1900s considered Rodolfo’s at thatson, timeEnrico, the Italian RODOLFO COMERIO: founded in 1878 under this company nameexpandedcapital ofbythe textile Rodolfobusiness industry, by Comerioitdesigning started itsand business RODOLFO COMERIO is the oldest company in the World specialized in designing and manufacturingexactly with tooling designing machines demandedand manufacturing by the military industry grown in Italy in those years. in Busto Arsizio, Italy, considered at that time the Italian capitalcalenders of andtextile textile padders industry, and since it then the manufacturing plants for the production of rubber sheets and rubberized materials, His successor, Rodolfo, had the bright idea started its business by designing and manufacturing calendersto Companyorient and the textile hasCompany come padders atowards long way. the andcurrent entirely realized in Italy, which are matter of pride for the owners and for the Com- productionIn the ofearly machineries, 1900s whileRodolfo’s manufacturing son, Enrico, since then it has come a long way. In the early 1900s Rodolfo’stheexpanded first son, calenders Enrico,the installedbusiness expanded in Italyby fordesigning rubber and pany’s partners that will soon celebrate 150 YEARS OF HISTORY based on two pillars the business by designing and manufacturing tooling machinesprocessing,manufacturing supplied demanded tooling to Pirelli machines Industries by in demandedthe 1925, by that distinguish the company: andthe for military thermoplastic industry resins grown (PVC) in Italyprocessing, in those years. suppliedHis successor, to Montencatini Rodolfo, Group inhad 1942. the bright idea military industry grown in Italy in those years. His successor,Since Rodolfo, 1960 Rodolfo’s had sons theEnrico brightand Carlo, • CONTINUOUS TECHNOLOGICAL IMPROVEMENT to orient the Company towards the current idea to orient the Company towards the current productionthe of current machineries, owners and the Company’s with thefourth 1878 • MAXIMUM QUALITY of the offered product. generation,production have of machineries,definitely worked while towardsmanufacturing manufacturing the first calenders installed in Italy for rubberincreasingthe processing,first the calenders productivity installed supplied levels, in Italysteadily to for rubber updatingprocessing, the suppliedadopted totechnologies Pirelli Industries and in 1925, Pirelli Industries in 1925, and for thermoplastic resins (PVC)strengtheningand processing, for thermoplastic their leadership supplied resins in these (PVC) fields. toprocessing, TODAY For the rubber field,RODOLFO COMERIO proposes extremely sturdy and high-pro- In supplied1981 the companyto Montencatini moved to Group a new inmodern 1942. Montencatini Group in 1942. factorySince of 1960more thanRodolfo’s 35,000 sons sq.m Enricoin Solbiate and Carlo, ductivity calenders, provided with 2, 3 and 4 rolls in “I”, “S” and “F” shape, suitable , not far from its origins. Since 1960 Rodolfo’s sons Enrico and Carlo, the current ownersIn thethe followingcurrent and yearsowners the their and Company’sinnovation the Company’s has given fourth for all the production of: risegeneration, to a very wide have range definitely of products moreworked and towards fourth generation, have definitely worked towards increasingmoreincreasing theworldwide productivitythe exported, productivity which levels,nowadayslevels, steadily • textile fabric rubberizing for Industrial and car tires, steadily updating the adopted technologies and strengtheningrepresentsupdating thetheir 90%the of adoptedleadershipthe company technologies turnover. in and • PCR, TBR and OTR steel cord rubberizing for radial and giant tires strengthening their leadership in these fields. these fields. In 1981 the company moved to a new modernIn 1981 factory the company of movedmore to thana new modern • fabric rubberizing for conveyor belt production fabric rubberizing for printing blan- factory of more than 35,000 sq.m in Solbiate 35,000 sq.m in , not far from Busto Arsizio. In Olona,the following not far from its yearsorigins. their kets, life rafts, air springs and folding bellows innovation diversifies in a very wide range of products moreIn the followingand moreyears theirworldwide innovation has given • innerliner calendered material rise to a very wide range of products more and exported, which nowadays represents the 90% of the companyLeadermore worldwideturnover. plants exported,for plastics which nowadays • rubber sheets and stripes with roller- head calenders combined with extruders andrepresents rubber the 90%industries of the company turnover. • mixing rooms with 2-rolls calenders prearranged for the SSM (Single Step Mixing) In 2008, when the worldwide economy was affected by a global crisis, Rodolfo Comerio technology succeeded in overcoming the difficulties thanks to its ability to renew, to the study of new technologies and to the registration of very important patents for the production of plastic materials embossed in register with the underlying printed pattern In 2012Leader the Company plants started dealingfor plastics with rubber LEADER PLANTS FOR RUBBER applicationsand rubber other than theindustries ones for tire industry, thus immediately achieving another series of greatIn successes2008, when in the the field worldwide of rubberized economy fabrics was AND PLASTICS INDUSTRIES foraffected conveyor belts.by a global crisis, Rodolfo Comerio Sincesucceeded 2008 the Companyin overcoming has increased theby three difficulties TECHNICAL INFORMATION timesthanks its annual to its turnover ability toand renew, has consistently to the study of increasednew technologies its own percentage and to ofthe calenders registration of installed all around the World. In 2008, when the worldwide economy was affected by a veryglobal important crisis, patents RODOLFO for the production of All the achieved results seem to be COMERIO succeeded in overcoming the difficulties thanksovershadowed plasticto its materials abilityby the embossed latest to greatrenew, in success register toof with the RODOLFO COMERIO has been always designing, developing and manufacturing its theunderlying company, printedconsisting pattern in the manufacture of the study of new technologies and to the registration of verytwoIn huge2012 important calenders, the Company the biggest patentsstarted ever dealing realized for with in rubber own calendering lines entirely in Italy by engaging more than 1,000 technicians and updating the rubber calendering methods and for the productiontheapplications World: aof 4-roll plasticother calender than and thematerials a 5-rollones calender, for tire industry, craftsmen, with internal and external staff extremely loyal to the Company. havingthus giganticimmediately dimensions, achieving 5,000 another mm roll series of workinggreat successeswidth, 870 mmin the roll field diameter, of rubberized 30-ton fabrics embossed in register with the underlying printed pattern. In 2012weight for the each rollCompany and more than 60started containers The most important parts machined, finished and certified byRODOLFO COMERIO for conveyor belts. dealing with rubber applications other than tire industry, thusused immediatelyfor the shipment. achieving are the calender rolls, the heart of the plant, and to them the greatest attention is TheSince future, 2008 with the this Company huge project has increased combined by three new successes in the field of rubberized fabric materials withfortimes the conveyor otherits annual already turnoveracquired belts. ordersand has covering consistently devoted: they are made of the most resistant forged steel to obtain the best trans- almostincreased all the 2017,its own has percentagedriven the company of calenders Since 2008 the Company has triplicated its annual turnoverto installedhire manyand all additional aroundhas theresourcesconsistently World. and to build versal sheet profile and the selected bearings are the ones realized with the highest a Allnew 10,000the achievedsq.m production results plant seemthat will to be increased its own percentage of calenders installed all aroundenlargeovershadowed the the existing World. factory.by the latest great success of precision, with inner ring hot ground with the roll surface, at working temperature, All the achieved results seem to be overshadowed by thethe company,latest consistinggreat successin the manufacture of to reach a perfect longitudinal profile. two huge calenders, the biggest ever realized in achieved, consisting in the manufacturing of two huge calenders,the World: a the4-roll calenderbiggest and aever 5-roll calender, The strength of our calenders are the frames made of high thickness full steel to bear, realized in the World: a 4-roll calender and a 5-roll calender,having having gigantic gigantic dimensions, dimen 5,000 -mm roll without deforming, the lamination forces produced in the roll nip by the calendered working width, 870 mm roll diameter, 30-ton sions, 5,000 mm roll working width, 870 mm roll diameter,weight 30-ton for each weight roll and more for than each 60 containers material, as distinct from other manufacturers making use of light composite metal used for the shipment. roll and more than 60 containers used for the shipment. To supportThe future, thiswith growththis huge project trend combined sheets, more suitable for structures exposed to great accelerations as on tooling in future, it was decided to hire many additional resources andwith tothe buildother already a new acquired 10,000 orders covering machines. almost all the 2017, has driven the company sq.m production plant that will enlarge the existing one. to hire many additional resources and to build a new 10,000 sq.m production plant that will enlarge the existing factory. CALENDERING LINES FOR EVERY NEED

TEXTILE CORD RUBBERIZING RUBBERIZING OF FABRICS FOR CONVEYOR BELTS FOR INDUSTRIAL AND CAR TIRES The rubberizing of thick fabrics for the manufacturing of conveyor belts, with thick- The textile cord rubberizing is performed in a 4-roll, S-shaped calender, where two nesses even higher than 60 mm, has been one of the greatest successes obtained sheets are produced, each one adjusted in thickness through hydraulic shifting groups in the latest years by RODOLFO COMERIO calendering lines. at the sides, and with a cross-axis system in the center, then laminated at the same This success has arrived further to the huge developments that the Company brought time above and below the fabric between the intermediate rolls adjusted in distance, to these particular lines, much bigger and more complex compared to the lines for and then preferably corrected by pressure, with similar hydraulic devices at the the textile or steel cord rubberizing, with the integration of machines studied and sides and a roll-bending system in the center, with the automatic intervention of designed on purpose for each single customer. material thickness gauges. RODOLFO COMERIO has begun its intensive production The peculiarity consists in the manufacturing in line of the carcass up to its final rub- of these calendering lines since the middle of the last century, as a result of a fruitful berizing: that means making the confectioning of the multi-layer material composing collaboration with one of the major international players that started transferring its a conveyor belt for mining directly in line, with a system developed by RODOLFO know-how to emerging industries in different countries all around the world. COMERIO with very high lamination accuracy, simplifying and shortening the normal Utmost ease of operation, perfect control of settings, accuracy of the finished product, production cycle made through another process with long manufacturing times, lower ease of maintenance and long life of the machines are the distinctive elements of accuracies, more scraps and subsequent increase of costs. Even the min. – max. width RODOLFO COMERIO lines. of the carcass can considerably vary up to 4 times through electronic and mechanical adjustments of the tensions on the material in the different phases of the process, centering devices of the material for the different characteristics that the products takes by width variation and edge trimming systems of high-thickness carcass. PCR – TBR AND OTR STEEL CORD RUBBERIZING FOR RADIAL AND GIANT TIRES

The steel cord rubberizing starts from the single steel wires unwound from a creel, with RUBBERIZING OF FABRICS FOR PRINTING systems to place, to guide and control the position and the tension of each single wire. BLANKETS, LIFE RAFTS, AIR SPRINGS, The obtained wire-set is inserted between two rubber sheets produced in a 4-roll, S-shaped calender, adjusted in thickness through hydraulic devices at the sides FOLDING BELLOWS and with a cross-axis in the center, and then making them passing with the wire-set through the intermediate rolls, adjusted in distance as well, everything under the RODOLFO COMERIO optimized for these plants a new mix of news based on modern continuous control of product thickness gauges. techniques of design, innovative manufacturing and assembly systems, rigorous study The OTR rubberizing has been added in the latest years, requiring the use of forwarding of materials, special attention to the details and cutting-edge technology. rolls having a considerable diameter, consequently to the noticeable increase of the The extreme precisions required added to the complex and numerous kinds of thread- diameter of the steel wires for the manufacturing of giant tires, obtaining immediately ing and treatment of the materials have made up these lines, with 4-roll 30°-inclined a great success. I-shaped configuration, a real testing field suitable to experience new techniques. The combined rubberizing of textile and steel cord, completing the range, has been The devices to complete the calender are several and tailor-made based on specific realized for the first time byRODOLFO COMERIO, in order to fulfil the Customers’ requirements of customization of every customer. needs of making both productions with only one plant and only one investment. The production process of these lines is very peculiar and studied on purpose by RODOLFO COMERIO based on the various feeding of the rubber between the calen- der rolls in order to follow the different productions and fabrics used, finding huge consent by the manufacturers of these materials. TO COMPLETE ALL CALENDERING LINES

PRE AND POST CALENDERS ELECTRICAL EQUIPMENT

RODOLFO COMERIO is universally known for the excellence of its devices before and RODOLFO COMERIO gives value to the electrical equipment of its systems with after every calender for the treatment of fabrics to be rubberized, calendered rubber devices aimed to automatically adjust the feeding, the positioning, the control and sheets and rubberized textile and steel cord. Take a look at “Patents and innovations” the safety of the rolls. brochure to learn about the several projects realized and patented to make more • RC BANK CONTROLSystem* This system keeps constant and uniform the material performing, precise and effective the pre- and post-calender devices. bank quantity between the calender rolls, by adjusting the quantity and the homoge- In the textile cord lines of particular interest there are: neous distribution between stock-guides, by means of of CCD cameras with feedback • Unwinders & joining presses for bobbin tail-head fast connection to the 2-roll mill, to the stripe cutting device and to the belt speed and oscillation. • Drying of the fabric by rolls or oven to eliminate the humidity content • Material thickness measuring devices This system measures and keeps accurate • Centering & spreading devices for centreline position & fabric end-count the thickness, by means of scanning heads for the measurement of the rubber In the steel cord lines technically stand out: sheets produced between the calender rolls and for the total thickness measur- • Creel rooms with efficient devices to brake and control the tension of each cord ing downstream. Measuring source of this system can be laser, compressed air, • Thickness gauges to control the material profile, the end-count and the balancing ultrasonic or radioactive source. of the cords in the rubber • RC RUN SAFE PACK This pack manages the calender rolls shifting and positioning • Winding unit, to perform automatically the cut of the cords, the threading of the adjustment, carried out by hydraulic cylinders with closed loop position and pressure head and the unloading of the finished bobbin adjustment by means of proportional control valves giving 12,000 inputs/min, i.e. In the lines for conveyor belts for their innovations are in evidence: adjusting the position twice every 0.01 sec. and high precision electronic position • Cooling rolls independently driven to control the tension on material transducers in order to manage 3 very important systems. • Belt carcass wind-up table to automate the belt full construction In the fabric rubberizing lines to be put in evidence are: • Material pulling for the best collection and conveying of the rubber sheet to the different points of lamination • Unwinding and winding units indifferently used to wind or unwind the materials in the different production phases of the finished product RC RUN SAFE PACK

In RODOLFO COMERIO calenders, the system for the shifting and position adjustment of the rolls is composed by: • RC GAPSystem* It guarantees an accurate and constant thickness of the rubber sheet produced by the two couples of calender rolls 1-2 and 3-4 and of the product CALENDERS FOR OTHER PRODUCTS laminated between rolls 2-3 by means of an electronic computerized position control. • RC LAMINATINGSystem* It guarantees an even lamination between calender rolls 2-3 Besides to the wide and experienced product range here above, RODOLFO COMERIO of the two rubber sheets produced by the couples of calender rolls 1-2 and 3-4 for the can develop interesting solutions to satisfy every Customer’s need. The uncountable perfect lamination and deep penetration of the rubber in the textile or steel cord web. realizations providing the best solution for all needs confirm this versatility. • RC ROLL SAFESystem* It avoids unforeseen and damaging contact between two • Lines for innerliner production with 2+2 roll calenders complete with specific calender rolls (1 against 2, 2 against 3, 4 against 3), by means of an electronic pre and post calender equipment control of the minimum closing of lamination GAP of each roll side, allowed and set • Lines for complex materials production with 4-roll calenders by the operator through the management software, and of maximum lamination • Profiling lines for bead filler with 3-roll calenders strain, read out by the same pressure transducers of the RC LAMINATINGSystem • Textile cord rubberizing and rubber sheet production lines with 3 or 4-roll calenders and it performs the fast roll opening as well. • Roller-head 2-roll calenders with extruders to produce rubber sheets and stripes • 4 RC SF – FREESystem* FRICTION FREE SLIDING SYSTEM Rodolfo Comerio now obtained • 2 or 3-roll calenders for mixing rooms, prearranged for the SSM technology the PATENT for the application of a sliding system with a very low friction on the • 2 or 3-roll profiling and calibrating calenders, provided with a system for the profiling supports of roll 2, that allows to cooperate and replace, with very good results, the roll quick change classic NIP 2-3 adjustment by distance with the brand-new regulation by pressure. Leader since 1878 Rodolfo Comerio S.r.l. Via 4 Novembre, 165 - 21058 Solbiate Olona (VA) ITALY Tel. +39 0331 641680 - Fax +39 0331 641666 [email protected] www.comerio.it

COMPANY WITH QUALITY MANAGEMENT SYSTEM CERTIFIED BY IIP :

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