Badger Roll

Badger Roll
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Embossing Roll Click to Close Click to Open

The following information is provided as a review of fill 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.

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Textile Rolls Click to Close Click to Open

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 will result in a High Quality Filled Roll, which will help maximize your productivity and performances from Calender, Textile, and Embossing.

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Super Calender Roll Click to Close Click to Open

The following information provided is a review of fill material available for fiber filled Calender Rolls.

The most common roll fill 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 and High Heat Applications

6. BRFM Specialty Calender Roll Material
Black 10% Linen, 90% Denim Cotton 300gsm
High Density Calenders and 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, and 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

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Moonstone Click to Close Click to Open

SPEC - Moonstone Epoxy/Teflon Roll Covering Compound is a superior compound of a finely woven mat impregnated with a unique composition of epoxy and Teflon.  The material is applied directly to your roll core under heat and high tension without the need for any bonding agent or adhesive.  The material is then thermally cured at temperatures up to 350° F (177° C).  This combination of the wrapping process and the curing cycle results in a hard, durable, corrosion-free covering which is stiff, but lightweight and long-wearing.  As machine speeds and wire/fabric tensions increase, many papermakers have discovered that traditional rubber covers deteriorate resulting in reduced forming fabric life.  MOONSTONE’s special formulation, combining epoxy and Teflon, results in a bone-hard cover exhibiting exceptional “non-stick” characteristics even in the harsh wet end atmosphere.

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Reel Tuff Click to Close Click to Open

SPEC- Reel Tuff Anti-Static Roll Covering Compound has the same outstanding properties as our Jadestone™ Roll Covering Compound, which is used throughout the Paper Machine – wet end or dry end.  The unique difference is that our REEL TUFF Roll Cover performs as an electrical conductor.  The REEL TUFF Covering Compound is a unique composition, combining extremely high tensile and compressive strengths with a superior bonding capability.  These covers are applied directly to your reel spools and roll cores without the need for a bonding agent and the problems associated with them.  The covering cannot separate from the core, crack, break, fray or expose jagged edges on the surface of the roll.  SPEC - REEL TUFF will eliminate all safety problems related to the discharge of static electricity due to high speeds in dry environments.

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JadeStone Click to Close Click to Open

SPEC - Jadestone™ epoxy composite material is a superior composition of a finely woven mat impregnated with epoxy resin.  Our curing process incorporates temperatures above 350°F.  This combination provides a hard, durable, corrosion-free roll covering, which is lightweight and long wearing.  Jadestone™ is one-half as light as aluminum, nearly as hard as chilled iron, three times as durable as hard rubber and will polish to a 15 RMS micro finish.  Jadestone™ epoxy composite has a finer finish than ‘fiberglass’ roll coverings and will not break, fray or separate and it helps increase the stiffness of the roll body, thus reducing deflection.

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Sheraton Click to Close Click to Open

The papermaker has long recognized that a 4-5 Hz shake applied throughout the forming section of slow speed paper machines (i.e., less than 200 FPM or 60 m/min) is perhaps the most favorable environment available for producing uniform, quality papers.  This situation exists because such a shake creates an almost continuous oscillating CD shear or fine-scale turbulence throughout the forming zone.

However, few paper machines run this slow any longer.  When a comparable shake is applied to a high speed machine, like one running at 2000 FPM, it introduces a fresh CD pulse into the stock only once every 3-4 feet of travel down the machine, thereby losing most of its effectiveness.

So few machines today running over 1000 FPM employ a shake.  Instead, they depend on a number of other devices, primarily free-draining and vacuum-augmented foils to maintain stock dispersed throughout the forming zone.  These devices have never been as effective as a 5 Hz shake on a 200 FPM machine.

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Manufacturing Click to Close Click to Open

Badger Roll & Machine is committed to helping you, along with our many years of experience, with all types of roll manufacturing.  This includes bearing diameter repairs, re-journaling, manufacturing new complete and machining capabilities, associated to breakdown situations related to the paper, textile, converting and other heavy industries, makes us your number one choice.  Our friendly experienced staff is always ready to help serve your needs.

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Balancing Click to Close Click to Open

We are proud to announce the final installation of our new American Hofmann Balancing Machine.  The following is for your review of the machine capacities.

70,000 Lbs. - maximum weight of a rotor mounted in its own bearing housings

50,000 Lbs. - maximum weight of a rotor mounted directly on the bearings of the pedestal stands

150 Lbs.  - minimum Weight capacities

94.00" - maximum diameter of rotor over the bed area

69.00" - maximum diameter of rotor over the belt tensioner

445.00" - maximum length between stands

50 HP Drive System

Balancing speeds infinity variable, dependent on drive diameter of rotor

Windows 2000 control system, with PCX Electronics

Printing package for printing reports for balance and unbalance

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Emergency / Breakdown Services Click to Close Click to Open

We understand breakdown situations happen and we are dedicated in helping you get back up and running.  We provide 24-hr. emergency breakdown services for the following:
  • Reel spools
  • Wire return rolls
  • Uni-rolls
  • Segment rolls
  • Specialty rolls (all types)
  • General machining (all types)
  • Assembly services

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Farrel Grinder Click to Close Click to Open

We recently installed a High Precision Farrel Two Wheel Roll Grinder.  The machine was recently updated with all new Solid State AC electronics and during the install, each piece of the machine was gone through and brought back into factory specifications.  The machine was fitted with a new Roll Track Measuring System.  The new system is capable of measuring and recording Roll Profile, Crown, Compound Crown, Dubbing, T.I.R. Readings, Concentricity, Two Plane Concentricity, Roundness and Tracking Measurements.  The machine has a maximum roll diameter capacity of 60.00” with a maximum roll face width of 315”.  The machine can handle a maximum roll weight of 120,000 Lbs. and can grind the smallest roll diameter of 8.00”.  At the same time, a new Belt Grinding Attachment was also fitted to the new Farrel Roll Grinder.  The new belt grinding attachment will allow us to be more versatile towards our customers needs associated to grinding various types of roll covers.

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Types of Grinding Click to Close Click to Open

Roll Grinding - Farrel (2) Wheel
  • Wheel Head 25 HP – Spindle Speed Range, B1 Directional
  • Programmable 100 – 1200 RPM, Grinding Wheel Size 3” Face x 20” Diameter
  • Headstock 50 HP – Work Speeds 4 – 24 RPM Programmable
  • Carriage 10 HP Speeds 2 – 60 IPM. Carriage Ways Center to Center 66” Overall Length Carriage Ways 88”
  • Maximum Diameters Ground 42” On Center and 60” Below Center
  • Minimum Diameter Ground On Center 8” Maximum Roll Body Face Length 315”

Equipped With The Machine

  • A new Belt Grinding Attachment
  • A new Roll Track Measuring System
  • The system is capable of measuring & recording Roll Profile, Crown, Compound Crown, Dubbing, T.I.R. Readings, Concentricity, Two Plane Concentricity, Roundness & Tracking Measurements
Arter Surface Grinder
Table Size - 32” Diameter Magnetic

Gem Superfinisher
Serial # 93099

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Superfinisher Click to Close Click to Open

Gem Superfinisher allows us to finish your rolls to a 2 RA or better, if necessary.  Such polished finishes are important for surfaces in a variety of industrial applications, such as printing, food, pulp paper, coated, coating tools and a variety of other industrial applications. We have more than 75 combined years in relation to Grinding and Superfinishing of the following rolls:
  • Chilled Cast Iron
  • Chromed
  • Steel
  • Stainless Steel
  • Brass
  • Granite
  • Rubber
  • Ceramic
  • Hard Face Coatings
  • Composite Covers
  • Epoxy Composite Covers
  • Polyurethane

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