Roll manufacturing
Rolls are widely used in film and sheet extruders, slitters, stretching machines, coater machines, paper making related machines, and other machines, and they are high-precision industrial components despite their simple appearances. Our technical capabilities backed up by our many years of experience working in this industry enable us to manufacture and machine rolls for any kind of application and with any level of precision.
Metal roll manufacturing
We have an integrated system capable of producing various types of rolls (such as jacket rolls, knife rolls, coating rolls, and guide rolls) all in-house, from manufacturing and machining through to surface treatment and final surface finishing.
Roll manufacturing process

Types and characteristics of rolls
Casting roll
Required characteristics
Specularity, surface roughness control, cooling efficiency, etc.
Characteristics of casting rolls manufactured by Otec
  • We can handle a variety of surface finishing, ranging from ultra-mirror finishing (0.05S or lower) through to various types of satin finishing.
  • We can handle a variety of internal structures that enhance cooling effects, according to customer requests. (Double tube, periphery, spiral, bored, etc.)
Casting drum Spiral cylinder inside a roll
Polishing roll
Required characteristics
Specularity, surface roughness control, roll accuracy, etc.
Characteristics of polishing rolls manufactured by Otec
  • We can handle a variety of surface finishing, ranging from ultra-mirror finishing (0.05S or lower) through to various types of satin finishing.
  • We can handle mirror pocket finishing that aims at both blocking prevention and specularity.
  • We can manufacture and machine high-precision rolls with a roll accuracy level of 2/1,000 mm or less.
  • We can handle a variety of internal structures that enhance cooling effects, according to customer requests. (Double tube, periphery, spiral, bored, drilled, etc.)
 
Mirror surface polishing roll  
Preheating and cooling rolls
Required characteristics
Cooling efficiency, heating efficiency, surface temperature uniformity, etc.
Characteristics of preheating and cooling rolls manufactured by Otec
  • We can handle a variety of internal structures that enhance cooling and heating effects, according to customer requests. (Double tube, periphery, spiral, bored, etc.)
  • Using our proprietary surface treatment Tfe-Lok can prevent the adhesion of dirt such as oligomers at a preheating or cooling stage. (For details, refer to the section Tfe-Lok.)
Stretching roll
Required characteristics
Specularity, surface roughness control, etc.
Characteristics of stretching rolls manufactured by Otec
Suction roll
Required characteristics
Machining vacuum or blowout holes
Characteristics of suction rolls manufactured by Otec
  • We have a track record in machining suction rolls with 10,000 holes for use in metal foil forming lines.
  • Surface roughness can be adjusted.
  • Good plating can be achieved regardless of the number of holes.
Embossing roll
Required characteristics
Pattern specifications, engraving accuracy, etc.
Characteristics of embossing rolls manufactured by Otec
Coating roll
Required characteristics
Roll accuracy, specularity, etc.
Characteristics of coating rolls manufactured by Otec
Knife roll
Required characteristics
Roll accuracy, blade edge accuracy, blade edge linearity, etc.
Characteristics of knife rolls manufactured by Otec
  • We can create sharp edges by precision surface grinding for blade edges.
  • We can handle rolls that allow blade edges to be attached and detached.
  • We can machine rolls with high accuracy in the order of microns.
  • We can maintain used rolls.
Blade edge of knife roll Acute-angled knife roll
Replaceable-blade knife roll Replaceable-blade knife roll
Rolling roll
Required characteristics
Roll accuracy, specularity, hardness, etc.
Characteristics of rolling rolls manufactured by Otec
Guide roll
Required characteristics
Lightweight, specularity, etc.
Characteristics of guide rolls manufactured by Otec
Aluminum guide roll Carbon roll
Three-layer structure (carbon, copper plating, and chrome plating)
Roll machining facilities
General-purpose lathe 6 units (We can machine rolls with maximum dimensions of 600 mm diameter × 6,000 mm long in-house. For rolls larger than the maximum dimensions, we outsource them to our partner companies.)
Machining center 1 unit
Radial drilling machine 1 unit
Vertical milling machine 1 unit
Cylindrical grinding machine 3 unit
Dynamic balancing machine 1 unit
Others Welding equipment etc.
Manufacturing elastic rolls
Elastic rolls are mainly used as calendar rolls for finishing processes in industries such as paper making, textile, various types of film, and aluminum foils. When materials such as paper or cloth are processed, nipping them between a steel roll and an elastic roll can form them into a smooth and glossy product. It is also possible to transfer dents to an elastic roll beforehand by using an embossed steel roll, and nip a material between the elastic roll and embossed steel roll. This kind of technique is used to form products. Using elastic rolls in such a way can add a variety of values to products. We can manufacture and machine elastic rolls with maximum dimensions of 820 mm diameter x 3,800 mm long, and with a maximum weight of five tons.
Comparison of characteristics of different elastic rolls
Type of elastic roll Appropriate hardness
Hs/D
Maximum nipping pressure
kg/cm
Maximum speed
m/min
Effect
New Cotton Roll 70-80° 250 300 Glossiness effect
Woolen Paper Roll 82-86° 300 700 Smoothness and glossiness effect
Special White Cotton Roll 82-88° 450 1000 Smoothness and glossiness effect
Milcon Paper Roll 87-90° 500 300 Heat resistance Nipping pressure resistance
(The figures in the table are applicable when a regular break-in is complete and load is applied evenly to rolls.)

Roll type New
Cotton Roll
Woolen
Paper Roll
Special White
Cotton Roll
Milcon
Paper Roll
Characteristics
Maximum hardness Hs/D 82° Hs/D 86° Hs/D 88° Hs/D 91°
Surface limit temperature 80℃ 80℃ 95℃ 130℃
High-speed operation resistance × ×
Pressure resistance ×
Resiliency ×
Heat resistance × ×
Smoothness ×
Durability ×
Break-in period Long Long Short Short
Quality variation
Hardness variation
Washability ×
Glossiness/temperature evenness
(◎: Excellent, ○: Good, △: OK, ×: No good)