Tallinn University of Technology

EKP0612 – Technology of Plastic Industry 2

“CALENDERING”

Referative Work 01

Student Name: Farzan Yahya Habib

Student ID: 194228 KVEM
E-mail: farzan.habib10@yahoo.com
Program: MSc.Plastics
*Introduction: Calendaring was developed in the early 20th century to make rubber sheets used to
produce treads for tires. This process is still used today for elastomers, but it was considerably developed
in the mid-20th century for the manufacture of packaging (rigid PVC), oilcloth, or imitation leather
(plasticized PVC). Nowadays, PVC compounds are sometimes replaced by polyolefin compounds, but it
is still marginal. In contrast with extrusion or injection moulding machines, where all the transformations
occur in the same machine, the calendaring process consists of successive units that each play a specific
role.
Types of Calendar Calendaring covers two distinct types of processes: Film calendaring, to produce thick
sheets (from 300 µm to a few millimeters), typically for PVC or elastomeric compounds. Most calendaring
machines contain more than two rolls (up to five in some cases) with a controlled temperature close to the
temperature of the polymer. This process is characterized by the existence of a large “bank” of material
upstream from the gap between each pair of rolls. Post-extrusion calendaring used to improve the thickness
uniformity and to cool down a polymer sheet or film downstream of an extrusion line. These calendaring
machines have two and sometimes three cooling rolls. The “bank” of material upstream from the gap
between the rolls is much smaller, or even invisible to the naked eye. This finishing calendaring process
may be applied to any type of thermoplastic polymer.
*Components & their Function: Figure 1. presents a typical calendar line for manufacturing PVC sheet.
A typical system is composed of 1. Plasticising unit, In the plasticizing unit, which is represented by the
internal batch mixer and the strainer extruder, the material is melted and mixed and then fed in a continuous
stream between the nip of the first two rolls, 2. Calendar, Once the material is fed to the mill, the first pair
of rolls controls the feeding rate, while subsequent rolls in the calendar calibrate the sheet thickness. Most
calendar systems have four rolls as does the one in Fig.1, which is an inverted L- or F-type system. Other
typical roll arrangements are shown in Fig. 2 and 3, 3. Cooling unit, The sheet is then passed through a
series of chilling rolls where it is cooled from both sides in an alternating fashion, 4. Accumulator and
Wind-up station, After cooling, the film or sheet is wound.
One of the major concerns in a calendaring system is generating a film or sheet with a uniform thickness
distribution and tolerances as low as ± 0.005 mm. To achieve this, the dimensions of the rolls must be
precise. It is also necessary to compensate for roll bowing resulting from high pressures in the nip region.
Roll bowing is a structural problem that can be mitigated by placing the rolls in a slightly crossed pattern,
rather than completely parallel, or by applying moments to the roll ends to counteract the separating forces
in the nip region. Calendaring can be modeled by assuming steady state, laminar flow and isothermal
conditions.
*Materials & Application: Predominantly used for PVC however, other materials such as modified PE,
polypropylene (PP), and ABS could also be calendared. Products range from wall covering, sheeting,
upholstery fabric, floor tiles, conveyor belts, shower curtains, coverings for car interiors, pool liners, and
inflatable boats to agricultural mulching materials.
*Calendaring problems: There are several problems that one can encounter when producing polymer
sheets by calendaring. The sticking of the sheet on the last roll of the calendar could make it difficult to
extract. In the same manner, the sheet may stick to the upper roll instead of being driven by the lower one
at the gap exit. To remedy this problem, one can add an external lubricant to the compound, but if in too
large quantity this lubricant can affect the flow of the polymer between the calendar roll.
*Summary: As with plastics processing, some of the principles are basic, but actual on the floor experience
reveals many ways that a calendaring is a very special and unique technique for processing plastic
films/sheets and may require trouble shooting. There are many factors to be considered and using some of
the design principles and processing recommendations made should help technicians get the most out of
their equipment.
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 *Figures Related to Calendaring Unit*

(Figure 1)
Schematics of Calendaring Unit

(Figure 2) (Figure 3)
Calendar Arrangements Schematics of Calendaring Process

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 (Figure 5)
(a) Elastic deformation of the roll, (b) Correction of the elastic deformation of the
roll by applying constraints outside the bearings, (c) Misalignment of the rolls (top
view)

(Figure 6)
Calendared films and sheets

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*References:
• Polymer processing principles and modelling (second edition) - Chapter 8 Calendaring
• Material Science of polymers for Engineers – Chapter 6.6 Calendaring
• Introduction to plastic engineering – Chapter 5.9 Calendaring
• https://www.bpf.co.uk/plastipedia/processes/calendering.aspx
• https://www.plastixportal.co.za/calendering-process-for-plastics.html