Badger Roll & Machine - Our Products -> Filled Rolls

Embossing Roll The following information is provided as a review of filler material available for filled back up embossing rolls:

The most common embossing roll fill material used is BRFM hard blue denim cotton. This material is also available in white, as preferred by the customer. The normal hardness range is 82 / 84 and 84 / 86 Shore D durometer. A roll filled with this material offers good pattern retention and web release.

Badger O.N.E. fill material offered only through BADGER ROLL & MACHINE, has become a common roll filler material. This material is a white synthetic and is not currently available in blue. The normal run-in time is about 2-hours and normal shore D Dourometer of 72-78 as preferred by customer.

One of the benefits would be, paper does not cling to the roll. Example on a normal fill roll when moist tissue paper is run against it, the tissue paper has a tendency to stick to the roll. This in turn causes wraps and damage to the roll cover. The Badger O.N.E. fill material does not have this characteristic with damp paper. After a wrap up, this special material can recover and rebound quickly.

Some converters and embossers have experienced increased filled roll life with the Badger O.N.E. fill material. Reports indicted roll life has more than doubled in addition to less down time at initial run-in, compared to that of regular hard blue filler material. Moderate heat from a heat gun applied carefully has been used to remove marks by swelling. Typically, these marks are indentations or impressions caused by foreign material passing through the nip. The caution of controlled heat is made, because this synthetic material can burn or melt very quickly. This heat repair method is a substitute for pegging or plugging marks in the roll surface to extend life and less down time.

The cost of a complete roll containing Badger O.N.E. fill is generally 3 times that of normal hard blue material filled fiber embossing roll. The run in time is about 2-hours verses about 8-hours for BRFM Hard Blue filled roll. The Badger O.N.E. Fill roll is run-in dry, no water used during the run-in procedure. Caution should also be taken not to force the procedure, as heat will cause the roll to swell.

35% Blue Wool No. 4, material has some of the same advantages of our Badger O.N.E. fill material; the material is more resilient over the standard hard blue materials and has less memory associated to roll wrap-up. Run-in time is about 8 hours depending on pattern type, normal Shore D of 78 to 82. If the rolls wrap-up, you can remove the material from the nip and rerun-in the rolls for removing minor imperfections caused from wrap-ups, a water solution should be applied on first run in.

20% Blue Wool No. 8 material is another commonly used embossing roll filler material. Tissue/toweling converters that produce a pebble finish with a male/female pattern prefer it. There are other wool/cotton grades of material available, such as high wool, used in deep or difficult pattern applications. The normal hardness range is 80 / 82 shore D durometers.

Textile Rolls Badger Roll & Machine uses specific formulas for each roll to ensure the maximum density and maximum amount of filler weight, which goes on every roll we build. Each roll, filled in sections, aged at specific tonnages; the result is a High Quality Filled Roll which will help maximize your productivity and performances from Calender, Textile, and Embossing.

Super Calender Roll The following information provided as a review of filler material available for fiber filled Calender Rolls:

The most common roll filler material used is Badger Roll Filling Material Hard Blue Denim Cotton. This material is also available in White, as preferred by the customer. The normal hardness range is 89 / 91 Shore D durometer.
The Following: are different grades of material offered from Badger Roll & Machine.
Quality Type	Application:
1. BRFM Blue Calender Roll Material 100% Cotton, 200gsm or 300gsm.	Coated and Uncoated Papers
2. BRFM White Calender Roll Material 100% Cotton, 220gsm or 300gsm	Coated and Uncoated Papers
3. BRFM Green Calender Roll Material 100% Cotton, 300gsm	Coated and Uncoated Papers
4. BRFM Calender Roll Paper "VT" 100% Cotton Special Sorted, 90gsm	Audio – Video – Magnetic Computer Tape.
5. BRFM Specialty Calender Roll Material 50% Linen, 50% Cotton, 140gsm	High Density Calenders High Heat Applications
6. BRFM Specialty Calender Roll Material Black 10% Linen, 90% Denim Cotton 300gsm	High Density Calenders High Heat Applications
7. BRFM Calender Roll Material 10% Wool, 90% Cotton, 140gsm	Coated and Uncoated Papers
8. BRFM Calender, Embossing Roll Material 18% Wool, 82% Cotton, 150gsm	Coated and Uncoated Papers Flat Embossing
9. BRFM Calender, Embossing Roll Material 3%-4% Silicone, 35% Wool, 65% Cotton, 180gsm	Embossing, and Textile Calender
10. BRFM - 80 Calender Roll Material 80 to 85 Lb. Material, 100% Cotton Blue, White or Green in Color	Coated, Lightweight Coated Uncoated, Newsprint, & Glassine
11. BRFM Calender, Embossing Roll Material 50-60% Wool, 40-50% Cotton, 250gsm	Schreiner Calender Aluminum Embossing,Silk Finish,Textile Calenders, Replacement for Raw Cotton Rolls, Fax Paper Calender
Special Material Blends Filter Materials
12. FM Material, Textile Calenders XL – Soft, Shore D 76 - 83 Top Temperature 375 Degrees	Schreiner, Rolling, Friction, and Nonwovens Calenders
13. FM Material, Textile Calenders 33.1/3% Khaki Wool Soft, Shore D 75 – 82 Top Temperatures 375 – 400 Degrees 33.1/3 % Khaki Wool No. 4 Shore D 79 – 84	Schreiner, Rolling, Friction Bonding, Nonwovens, Flat Finishing, and Water Mangles
14. FM Material, Supercalender 65 Lb. Material, 100% Cotton White, or Blue in Color Shore D 88 – 91	Coated, Lightweight Coated Uncoated, Newsprint, Glassine
15. FM Material, Embossing 35% Blue Wool No. 4 Shore D 82 – 84 20% Blue Wool No. 4 Shore D 83 – 85 20% Blue Wool No. 8 Shore D 84 – 86 65 Lb. Blue 100% Denim Cotton Shore D 84 - 90	Coated or Uncoated Paper Wallpaper, Napkins and Lace

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