Post Press Folding Machine Roller CNC Machining Processing Spare Parts

Think of fold rollers as a consumable item. The fold rollers are the heart of the folding machine and most today are made from a combination of steel and urethane or rubber. As solid as they are, they wear with use.

Think about how well the machine runs with new rollers.

· Make-ready is much faster with few adjustments needed

· Paper jams decrease and there is less waste

· Quality is better

· Run speeds are higher

Roller wear is slow and it takes an insidious, almost unnoticeable toll on productivity. If you track production, you’ll see it in the averages. If you don’t, you’ll notice that you’re working harder with more overtime. For a high-volume folding operation, a loss of even 5-10% fewer sheets per month equals a big loss of time and money over the course of the year, probably far more than the cost of roller upkeep.

To check if rollers need replacement, insert a strip of light text stock at each end of the roller and set evenly for a light drag. Then insert 3 strips, one at each end and one in the middle. If the middle sheet has no grip, it’s time for new rollers. Repair or replace rollers, springs, washers and bearings as needed and you’ll see an instant boost in bindery productivity.

Follow manufacturers’ directions for setting the rollers

· It only takes a few minutes to set with calipers

· It extends the life of the rollers

· It improves quality overall

· You can always 'cheat' if you need to add pressure but be sure to re-set when done

The key factor determining the suitability of folding rollers for the modern bookbinding industry is grip. Coated paper, glazing paper, peritoneal paper and heavy ink on the paper all pose challenges to the folding quality. If the folding rollers do not have enough grip, it will be difficult to precisely control smooth paper and ultra-lightweight thin paper.

Other important factors to consider are the durability of the folding roller, the cost of repair and reinstallation, and whether it is likely to leave nasty marks on the folded product.

Types of folding rollers:

1. Steel

Steel folders are durable and inexpensive, but impractical in many situations today. The folding rollers will have insufficient grip due to the unevenness of the steel surface, and cannot hold coated paper and other smooth papers.

Indentation is a common problem. It takes strength to control the paper, and as the pressure between the folding rollers increases, it is easy to leave uneven marks on the roller shafts on the paper. Therefore, steel folding rollers generally require longer setting time, slower running speed, poor folding quality, and serious waste.

2. Rubber roller

Rubber rollers, or polyurethane (PU) folding rollers, have better grip than steel folding rollers, but are less durable. All-rubber rollers have a relatively short lifespan. As the folding rollers wear, the grip becomes weaker and weaker. In order to control the paper, you need to increase the pressure, and the greater the pressure, the faster the wear of the machine. The result is time-consuming and costly equipment updates and failures, decommissioning

3. Hybrid

Or called a combined folding roller, which is composed of steel rollers and rubber rollers alternately. The width of each section varies from design to design. Some folders have 30% rubber in their surface area, while others are 40% or 50% rubber.

The combined folding roller combines the advantages of steel roller and rubber roller, and its grip and durability are better. But at the same time it also combines the shortcomings of both. When the rubber part starts to wear down, the grip weakens and the indentation problem arises. Renewal and reinstallation of folders is costly and time consuming.

4. MBO spiral pattern folding roller

It perfectly combines the advantages of steel folding rollers and rubber folding rollers, and avoids the disadvantages of combined folding rollers. The Spiral Folder is a patented product exclusively designed and produced by MBO. The 70% rubber surface provides good grip on all types of paper, including extra thin paper like Bible paper and smooth coated paper. Steel thread prolongs the service life of folding rollers and avoids creasing. Greater grip means less pressure, which means less wear, less creasing and less static.

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