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  Site Updated: February 1, 2012

Universal Urethane roll covering process
produces high quality roll coverings

Urethane Mixing Machine Universal UrethaneRolls are either received by commercial freight or by our own fleet of trucks, which covers an extensive area across the Midwest and beyond. Our quality procedure starts with an incoming inspection of the roll. This inspection includes reviewing a checklist which when completed is affixed to the roll. Any necessary core or journal repairs are reported to the customer. Once approved, these repairs are economically completed in our in-house machine shop.

After the rolls have been approved for recovering, they are stripped clean of all previous material, degreased thoroughly, and a bonding agent applied to ensure permanent bonding between metal and urethane. Universal Urethane can recover rolls with the bearings and couplings in place. Since the bearing and couplings are not removed, you save money on replacement and journal changes.

Following setup in a fitted mold and preheating in an oven to achieve proper casting temperature, the urethane is applied from one of our precision MAX/Metering/Dispensing machines. This technologically advanced equipment produces high quality cast rolls without porosity, cracks or voids.

The roll is then cured in a curing oven before the mold is removed. Curing time and temperature are carefully monitored. Proper curing time is critical to achieving a quality roll covering. The roll is also allowed a proper ambient cure time. This ensures the chemical curing process has been completed.

The roll is rough cut before being finished in one of our many grinders and lathes. The grinders and lathes are capable of accommodating rolls up to 60 inches in diameter and 20 feet in length. A roll finish is then applied according to customer specifications or our recommendation.

Before any finished project is shipped, it is subjected to a thorough final inspection process. This process ensures customer specifications have been met. Size, T.I.R., taper and durometer are among the many specifications noted. A copy of this inspection report is attached to each finished roll for customer records and a copy is kept on file at Universal Urethane for future reference.

The Five Steps of
Urethane Roll Covering

Step #1

Roll Inspection
After a roll is received, it gets completely inspected.  The core and shaft are UT / Mag tested if required.  All journal and core diameters are noted.  The condition of the cover along with its size and general appearance are noted.  Any bearings, couplings and gears that are on the roll are either removed and logged or left on the roll if it does not interfere with covering.

Step #2

Roll Prep
After incoming inspection, the roll is stripped of old covering.  The roll body is completely cleaned of old material and residue.  The roll is then steel shot blasted to produce a bondable surface.  This surface is then thoroughly degreased.  Then an adhesive is applied in two coats to enable urethane to metal bonding.

Step #3

Casting
The roll is baked for six to eight hours to enable the adhesive to bond to the steel and activate for urethane bonding.  A mold is placed around the core, which is slightly oversized from the diameter, and sealed into place.  Urethane is poured from a very sophisticated metering/measuring machine.  This machine ensures proper mix, no air bubbles and a uniform mix.  Once the mold is full, the roll is post cured for up to eight hours.

Step #4

Finishing
The cast roll is now sent to a finishing department.  The roll is machined down to the diameter and face width ordered by our customer.  Any grooving or crowning is completed in this area.  All surface finishes are also applied in this area.  Very tight tolerances and surface finishes are required by some industries.

Step #5

Final Inspection
After the roll is complete, every diameter is double checked and recorded.  The durometer, size, runout, and taper are all noted and checked to our customer’s specifications and order.  The journals are rechecked.  The balance of the roll is rechecked.  Everything is noted and stored with the record of this roll.  The roll is now finished and ready to be returned.

The Three Steps of
Urethane Part Development

Step #1

Part design
A custom molded part can be made from an existing part, a print, or a sketch. Once the professionals at Universal Urethane Products have the information we need, we send a detailed quote for the parts and any tooling needed to produce the part. Once a mold is made, the parts durometer (hardness) and color can be changed with no added tooling costs. Tooling costs are very inexpensive for custom molding. We also store and maintain your mold for future orders.

Step #2

Part manufacturing
Custom molded parts are made in our compression molding department. We pour our material into the cavity of the mold, place the mold in the compression press, and then squeeze the mold under heat and pressure to form your custom part. After a short period of time, the part is demolded and post cured. Once we have a mold for your parts, making parts is very simple. Should an emergency arise, we would make parts the same day as ordered for possible shipment the next day.

Step #3

Part finishing
Parts that have been made and postcured need to be cleaned and inspected. We take all of our custom parts to a deflashing area where the mold flashing is removed. The parts are then inspected for voids and other visual defects. They are spot checked against your print or sketch for size, durometer, color and general appearance. The parts are then shipped to you.

 

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