Premium range of covering compound

Paper Industry

              Based on roller operating conditions, ZENITH manufactures rollers for the paper sector. Large metal rolls (up to 10 metres long, 2 metres in diameter, and 50 tonnes WT) are manufactured, covered, and serviced using roll technology. Application, chemistry, speed, temperature, pressure, Roll geometry, deflection, balance, and coefficient of friction are all factors that influence roll quality. Among our offerings are:

1. New Core Design & Fabrication
2. Rubber Covering
3. Re-Grinds
4. Core Repair
5. Ultra sonic test & Balancing machine
6. Crowning
7. Grooving
8. Engineering Services
9. Extensive Field Support

DELIVERING DYNAMIC SOLUTIONS

Modern paper machines are built to manufacture/produce more at a faster rate. We have rubber-covering options that allow for optimum load usage without risk of crushing, as well as maximum covering resiliency, even at increasing hardness, in order to maintain a consistent Nip Zone.

SPECIALIZED COMPOUND

EXCEL

ULTIMEX

SUPER ROCK

ULTRA SUPER ROCK

ROLLS COVERING

Zenith has created a Premium range of compound Excel, Ultimex, Super Rock, and Ultra Super Rock with superior release characteristics, dimensional stability, chemical resistance, steam environment, thermal stability, and high pressure operation.        The material can sustain a Nip Load of up to 500 kg per linear centimetre. The graph below shows the newly developed superior compound.

SUCTION PRESS

COMPUTER DESIGNED NIP-SETUP
(IMAGE)
OFFERS THE BROADEST SELECTION OF ROLL COVERING MATERIALS AVAILABLE BASED ON APPLICATIONS
CNC DRILLING MACHINE – SUPPORTED BY GERMAN TECHNOLOGY
COVERING – AUSTRIAN TECHNOLOGY
POLYURETHANE & RUBBER COVERING FOR SUCTION PRESS

The Suction Press (SP) Concept provides a considerable improvement in suction roll cover performance. SP is a computerised method developed by Zenith engineers that determines a precise hole pattern for a mix of blind and through drilled holes in the press nip to provide more symmetrical sheet dewatering. The assertions that most suction roll applications can benefit from talking to SP are backed up by field findings.

HYBRID COVERS FOR PRESS SECTION

SUPERFLEX BD

“Superflex BD is a special hybrid compound developed with Italian technology. It is made out of specialized rubber & polymers to achieve better and wider NIP, dewatering, high linear load and much better resilience as compared to normal rubber covers. ” Superflex BD cover has been developed for High Speed and Long Run machine.

Cover Specifications Data:

1 Cover type Special Rubber
2 Colour Orange
3 Hardness 92–97º Shore A
4 Covering Thickness 18–20 mm

Physical Resistance

1 Abrasion Resistance Very Good
2 pH Range 4–10
3 Steam Resistance Good
4 Release Excellent
5 Temperature Up to 120º C
6 Tensile and Tear Strength High

Chemical Resistance

1 Acid Solution Good
2 Alkaline Solution Good
3 Hot Water and Steam Excellent
4 Ozone Good
5 Surface Roughness 0.8–1.5µm

BLIND DRILL

Advantages:

  • Improved cross-machine moisture profile
  • Longer felt life
  • Suitable for virtually all types of press sections
  • Better quality paper due to:
    • a) Smoother paper finish
    • b) Improved paper levelness
    • c) Better porosity features
    • d) Reduced linting
    • e) Improved printability
    • f) Reduced two sidedness
    • b) Improved cross-machine moisture profile
    • c) Longer felt life
  • Cost-effective due to enhanced runability, reduced energy use, and increased output.
  • We have a Drilling Machine that can drill suction rollers, Dri-Presses, and Dri-Pesses (B.D.R) within 12 hours, one roller can be drilled.

Does it work

  • Reduced energy costs
  • Reduced downtime and labour costs
  • Extended felt-life
  • Eliminated the need for purge showers
  • Increased tonnage

SERVICES WE OFFER ✓

  • New core design & fabrication
  • Rubber Covering
  • Crowning
  • Grooving
  • Regrinding
  • Core Repair
  • Ultrasonic test & Balancing
  • Engineering service
  • Extensive Support

CAPACITY

We have manufactured roller upto
following sizes:
Lengthn-8000mm
Diameter-2000mm
Weight-upto 30 tonne
We manufacture more than 100 new rollers per month. And the Roller size accuracy upto 5 microns is maintained. Shore hardness of Rubber & run out standards are properly adhered to for each & every roller.

Roll Grinder (CNC-Controlled)

Precision, performance, and dependability are the Zenith-Roll Grinding machine’s strong qualities. We’ve improved our Roll Grinder by taking into consideration shifting market conditions and requirements. Roll grinding machines from Zenith are made with extreme precision and high-quality materials. Precision, speed, and performance are all hallmarks of our machines. Our CNC driven roll grinders have an intuitive and adaptable machining interface, For automation technology, we’ve teamed with Siemens and Fanuc, and for measuring technologies, we’ve partnered with a number of other well-known companies. Our tailored automation systems were created with the needs of the roll grinding sector in mind. Our roll grinders are utilised in a wide range of sectors, including paper, steel, and aluminium, to name a few. Zenith manufactures all key components of the grinders within our engineering facility in Noida, India. We bring our decades of experience in roll grinding to each of our machines.

Salient Features

  • Precision roll grinding for smooth surface finish Ra value 0.5 µm
  • Roll crown (camber) setting for various size and crown
  • Cylindericity (Roundness) within 2 um/meter.
  • Fast and efficient grinding
  • Use friendly CNC interface Optional single set adjustable steady rest for rolls with 100 to 200mm diameter.

Offering Polyurethane & Composite Covering World Class Technology

Polyurethane Covering

Prepared with Special elastomers which have abrasion resistance properties. Designed for high speed and high demanding paper machines. PU Covering has lot more advantages than rubber and has proved its superiority by providing longer life, longer grinding intervals, better resistance to hydrophobisity,

Composite Covering

The Covering is manufactured from state of the art
materials such as an optimized combination of thermoset epoxy resin with special fillers and fibers for best performance. Its
benefits include:

  • Longer working life
  • Very long grinding intervals (10-12 years)
  • Higher resistance to temperature (up to 100 and even more)

Among our offerings are:

  • Rubber Covering
  • Re-Grinds
  • New Core Design & Fabrication
  • Core Repair
  • Ultrasonic test & Balancing machine
  • Crowning
  • Grooving
  • Engineering Services
  • Extensive Field Support

Delivering Dynamic Solutions

Modern paper machines are built to manufacture/produce more at a faster rate. We have rubber-covering options that allow for optimum load usage without risk of crushing, as well as maximum covering resiliency, even at increasing hardness, to maintain a consistent Nip Zone. 

Delivering-Dynamic-Solutions1
Delivering-Dynamic-Solutions2
Delivering-Dynamic-Solutions3

Specialised Coverings:

Polyurethane (PU)

The PU Covers are made from the most modern polymers, specially designed for the demanding conditions in paper machines. Our special coverings are mostly suitable for different types of Press & Size Press Rollers.

Polyurethane-Roller
Super-Flex

Super Flex (Hybrid Covers for Press Section)

Superflex BD is a special hybrid compound developed with Italian technology. It is made out of specialised rubber & polymers to achieve better and wider NIP, dewatering, high linear load, and much better resilience as compared to normal rubber covers.

Superflex Size/Rock is a special hybrid compound made up of Italian technology which can resist starch, oil, solvent, and sizing chemicals. It is very effective in starch slurry.

Composite Covering

Zenith Launches Nanotek & Nanorok Compoisite Compound. Composite calender covers are made of modern fiber reinforced compound. Special fillers ensure the optimal hardness, robustness and surface smoothness.

Advantages are depending on the existing situation and previously used roll covers:
• Improvement ofpaper quality
• Avoiding of paper blackening and paper mottling
• Higher bulk ofpaper
• Lifetime ofcover
• Marking resistance
• Allowing higher speed and load on machine
• Less downtime ofmachine
• Allows continues doctoring

Composite Covering

Nanotek and Nanorok have been designed for soft calendar presses and hard presses, respectively. With features like resistance to wear and chemicals, their use increases the life- span ofthe calendars along with a number of other benefits for its users.

1. Nanotek has the ability to withstand exacting working conditions for the soft calendar presses including — soft calendar, super calendar, multi-nip calendar, and mat on line calendar. Thus, it makes for a great choice of composite covers. Since the raw material used and the method of manufacturing results in an exceptional quality of finishing, there are no differences in surface texture or in processing paper. Due to low level of porosity of Nanotek, achieving excellent surface finishing is albeit easier. Moreover, the cover has excellent wear resistance ensuring the durability of the calendar.

Nanotek is recommended in the following positions.
• Soft Calender
• Mat-On-Line Calender
• Multinip Calender
• Super Calender

2. Nanorok is a composite cover for hard presses, which can also operate effectively in the most demanding operative conditions. It is recommended for a range of presses, including — hard press (wet environment), central press, hard-size press, and shoot press. The raw materials used as well as the efficiency in manufacturing enables the user to get a very good finish in their products. With this cover, all types of blades can be used while the life span is also increased and the good condition of the surface roughness and the press is maintained. Moreover, Nanorok is resistant to a number ofchemicals which are commonly used in the pulp, paper, and paperboard industry, including alcohol, acetone, acid chemicals, etc. It is also resistant to short exposures of oil and diluted caustic solutions.
Endowed with the ability to improve resistance to abrasion, it can significantly increase the lifetime of the presses.

Nanorok is recommended in the following positions.
• Hard Press (wet environment)
• Central Press
• Shoot Press
• Hard-Size Press

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