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INOMETA

PROTEK COATINGS

PROTECTION AND PERFECT FUNCTIONS


FOR ENHANCED PRODUCTIVITY
CONTENTS | 3

ADDED VALUE FOR ROLLS AND CYLINDERS:

INTELLIGENT, FUNCTIONAL COATINGS


The use of rolls made of steel, aluminium or composite mate- Durable anti-adhesion properties, electrical or thermal
rials in high-performance machines puts extremely high insulation and/or conductivity, traction or sliding properties
demands on surfaces. Inometa develops and manufactures as well as corrosion and wear resistance are features that
tailor-made coatings for various industrial applications. ensure your processes and continuously improve and thus
As needed, materials such as ceramics, metal, tungsten reduce your production costs significantly.
carbide or high-performance plastics are applied in con- Our exemplary development skills in coating processes with
trolled processes. In this way, we develop coating solutions advanced composites (CFRP/GFRP) create new industrial
for individual needs with maximum flexibility. standards which ensure that our customers have a constant
competitive advantage.

THIS BROCHURE PROVIDES INFORMATION ON THE FOLLOWING SUBJECTS:

PROTEK Coatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technology, Processes, Advantages and Applications at a Glance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applications Film Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Applications Converting Industry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Applications Printing Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applications Paper Industry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Products and Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Surface Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MULTIFACETED AND RELIABLE

COATINGS FOR EVERY REQUIREMENT


PROTEK coatings sustainably enhance quality, thus creating noticeable production advantages. They are specifically
tailored for rotationally symmetrical components such as rolls and cylinders which are used in the production of film, paper,
cardboard and textiles. In addition, surfaces with PROTEK coatings are used in the production of self-adhesive products and
in printing technology.
TECHNOLOGY, PROCESSES, ADVANTAGES AND APPLICATIONS AT A GLANCE | 5

As a DIN ISO certified company, we deliver consistent quality for maximum Inometa is dedicated to continuous product and process innovation so that our
customer benefit. customers can maintain their technological and economic edge.

Technology & Processes Productivity & Profitability Customer Benefits


At Inometa, thermal spraying technology is Investments must make sense from an eco- extended roll service life
used for the coating process. This technology nomic point of view. Thus, the economic ben- higher speed of production
is superior to other coating methods, as it can efit of a technical solution comes first for minimization of machinery downtime
be used for a variety of materials. Depending Inometa. The use of PROTEK coatings helps easement of surface cleaning
on the application, layers of metal, carbide or increase the performance of machinery and improved product quality
ceramics, as well as combinations with plas- equipment as well as ensure product quality.
tic can be applied and adapted to individual Application Scenarios
requirements. About the Company Examples of components, the technical and
Inometa is a market leader in the develop- economic characteristics of which we can
In addition, Inometa has developed a casting ment, production and distribution of web optimize through coatings, are as follows:
and winding method for stress-free applica- guiding, sensor and functional rolls, printing stretch rolls
tion of composite coatings. The rapid devel- sleeves and adapters, technical tubes and coating rolls
opment in the field of thermoplastics and functional surfaces. Our main focus is light- web guide rolls
thermosets opens up new material selection weight design, using aluminium and carbon crush cutter shafts
possibilities. Diffusion-tight coatings with high fiber composite materials to increase produc- fold and draw rolls
chemical resistance and high toughness are tivity and the associated added value. carrier rolls
just one example of the many possibilities. film rolls & dampening rolls
The addition of ceramic fillers or other wear- anilox rolls
resistant fillers makes for composite coatings treatment rolls
with excellent abrasion resistance. friction wheels
godets
inspection rolls
calender rolls

This list is a selection. For more application


examples, do not hesitate to ask us.
THERMAL COATING FUNDAMENTALS

PROCESS
Inometa has moved ahead in the development of thermal spraying parameters to provide an optimum protection against
static, dynamic, mechanical and chemical stresses for various components. With this method, a variety of combinations of
base materials and coating materials is possible. In essence, we have four differing applications that we use to resolve
different requirements.

Thermal Spraying with Wire or with Powder impact on the substrate, the very high kinetic introduced internally or externally. Special
Thermal spraying uses a flame of fuel gas and energy release makes for excellent adhesion nozzle configurations allow for similar particle
oxygen to fuse and/or melt the spray materials and very low porosity of the coating. As the velocities as generated in high velocity oxy-
before spraying it onto the workpiece surface spray material is not subjected to high tem- gen fuel spraying.
with the help of expanding combustion gases. peratures, strong metallurgical changes need
not be expected. Arc Spraying
High Velocity Oxygen Fuel Spraying (HVOF) In arc spraying, two metal wires are molten in
High velocity oxygen fuel spraying mixes fuel Atmospheric Plasma Spraying (APS) a high powered electric arc. The molten drop-
gas and oxygen in a combustion chamber In atmospheric plasma spraying, a high-pow- let ist atomized e. g. with compressed arc
where a constant high pressure ensures that ered arc and a gas (e. g. argon, helium, nitro- and projected onto the prepared workpiece
the resulting combustion is stable and uni- gen, hydrogen, or a mixture of these) are surface. The use of nitrogen or argon as atom-
form. The constant high pressure of the fuel- used to create a plasma beam that melts a izing gas can significantly reduce the coating
gas/oxygen-mixture propels a gas jet with a spray material which is most often introduced oxidation.
spray material out of the subsequent expan- as a powder. Depending on the desired heat
sion nozzle at supersonic velocity. Upon deposition rate, the spray material can be
MATERIALS | 7

SPECIFICALLY TAILORED FOR THE APPLICATION

MATERIALS
Increasing Production Capacity while Reducing Machinery Downtime

PROTEK Hard Metal Coating made of PROTEK Polymer Coating PROTEK Composite Coating
Tungsten Carbide or Chromium Carbide Special polymers or fluoropolymers, protected High performance coatings that have an
These extremely hard, dense, adhesive coat- by metal, ceramic or hard metal spray coat- excellent tensile adhesive strength on CFRP
ings offer a high degree of wear protection. ings are extremely wear-resistant functional and GFRP are very tough and highly resistant
They are resistant against erosion and abra- surfaces. They have special, durable non-stick, against chemicals. In connection with solids,
sion and can withstand impact and shock transport or sliding properties. As an example, this means perfect abrasion resistance.
loads. They are mostly used in the paper and PROTEK non-stick coating can be used on Electrical insulation or conductivity are
cardboard manufacturing industry as well as production rolls for hygiene and self-adhesive adjustable. The composite coating can be
in film production and finishing industries. products as well as in the printing, film, paper used both as an operating wear protection
and cardboard manufacturing industries. and as a specified layer for re-rubbering.
PROTEK Metal Coating
Metal coatings with high surface quality on PROTEK Ceramic Coating
cylinders made of CFRP/GFRP are an impor- A ceramic coating made of titanium, alumin-
tant building block for the use of lightweight ium and chromium oxides is resistant against
rolls in high-performance machines. friction and sliding abrasion. It will also pro-
In addition, PROTEK metal coatings can be vide wear protection to guide units for films,
used to increase an external diameter, as fibers, paper and cardboard. Defined sur-
repair coating for fitting surfaces or as corro- face structures ensure entrainment and air
sion and wear protection coating. exhaustion. Ground coatings have excellent
sliding properties. Depending on the stage of
processing, hydrophilic or hydrophobic prop-
erties can be created.
SOLUTIONS FOR CALENDER, CAST, BLOWN AND BIAXIALLY STRETCHED FILM PRODUCTION

APPLICATIONS FILM INDUSTRY

Film Production Especially for fast running machines, it is Surface Treatment/Inspection


Highly abrasion-resistant surface coatings possible to achieve additional air dissipation Surface treatment such as corona treatment
with very little porosity and excellent surface by specifically modifying the surface struc- requires highly abrasion-resistant ceramic
gloss are needed for film forming. Short ture. This effectively reduces airplaning coatings with excellent corrosion resistance
heating phases as well as scratch, cut and effects. Cut-resistant PROTEK coatings pre- and electrical insulation. In particular, having
shock resistance are significant prerequisites vent burrs caused by the use of cutters sufficient dielectric strength is a special chal-
of high-performance surfaces. on the rolls. Clean, scratch-free operation lenge for the surface. A light absorbing and
requires very good traction properties, espe- permanently homogeneous color scheme is
Example rolls: calender rolls, chill roll cially with low wrap angles or draw required for optical inspection systems that
rolls. A conductive surface is required to dis- detect surface blemishes.
Web Guiding sipate static charges from the product.
The use of PROTEK coatings which are spe- Example rolls: functional rolls, inspection rolls
cially adapted to the application effectively Example rolls: guide rolls, draw rolls, cutting
prevent adherence of various substances rolls, suction rolls, web edge control rolls and
such as glue, plasticizers and contaminants. tension measuring rolls, contact rolls and wind-
ing cores
APPLICATIONS CONVERTING | 9

WEB FINISHING AND PACKING SOLUTIONS

APPLICATIONS CONVERTING INDUSTRY

Applying/Coating as wear resistance can be regulated, or even sion resistance is especially called for due to
Special precision and lasting dimensional increased. Web guiding can be significantly waste products generated within the process.
stability are required in the domain of coating improved with PROTEK non-stick traction
and/or laminating units. Hydrophilic/hydro- coatings without causing scratches to the Example rolls: treatment rolls, inspection rolls
phobic surface properties can make signifi- substrate. If necessary, the surfaces can be
cant contributions to your process optimiza- made to be cut resistant. Cutting and Winding Technology
tion. PROTEK ceramic or hard metal coatings An excellent web guiding and tension sepa-
offer highest functionality. Example rolls: guide rolls, draw rolls, ration system is of utmost importance for a
suction rolls successful edge trimming process. PROTEK
Example rolls: coating rolls, coating cylinder, traction coating ensures that the substrate
laminating roll Surface Treatment remains flat on the rolls for a clean cut.
Surface treatment such as corona treatment To significantly increase the service life of
Web Guiding requires highly abrasion-resistant ceramic lower cutter shafts, Inometa has developed
The use of wear resistant PROTEK non-stick coatings with excellent corrosion resistance an extremely resistant hard metal coating.
coatings effectively prevent adherence of and electrical insulation. In particular, having
various substances such as glue, paste, hot- sufficient dielectric strength is a special chal- Example rolls: draw rolls, guide rolls,
melt adhesive, dust or any other contaminant. lenge for the surface. A light absorbing and cutter and contact rolls as well as winding cores
By specifically modifying the surface struc- permanently homogeneous color scheme is
ture and introducing polymer or fluoropoly- required for optical inspection systems that
mer, traction and non-stick properties as well detect surface blemishes. Excellent corro-
SOLUTIONS FOR GRAVURE, OFFSET AND FLEXOGRAPHIC PRINTING

APPLICATIONS PRINTING INDUSTRY

Web Guiding Printing Unit


Over lengthy periods, special PROTEK coat- PROTEK coatings can be either conductive,
ings effectively prevent the adherence of or thermally and electrically insulating.
various substances such as ink, paste, disper- Because the wear-resistant ceramic coatings
sions and contaminants. Especially with low come with adjustable surface energies (e. g.
wrap angle or draw rolls, very good traction hydrophilic or hydrophobic), different water/
properties are required to reduce differential ink handling and dosage functions are possi-
speeds and prevent paper jams. ble. The coating is made of high-quality
Rilsan polyamides which are applied free of
With tailor-made PROTEK coatings, web guid- pores. The highest precision during applica-
ing properties can be enhanced to a point tion and treatment of the coating ensure best
were airplaning effects are permanently and print results.
effectively reduced.
Example rolls: dampening rolls, bridging rolls and
Example rolls: guide rolls, web edge control rolls, doctor rolls, functional rolls, applicator rolls,
draw rolls, guide spindles, fold rolls, cutting rolls anilox rolls, film rolls, printing rolls, impression
rolls
APPLICATIONS PAPER | 11

COATING SOLUTIONS FOR ALL PAPER INDUSTRY SECTORS

APPLICATIONS PAPER INDUSTRY

Paper Guide Rolls friction and sliding abrasion. Therefore doc- traction are provided with proven PROTEK
For CFRP guide rolls installed in paper machi- tor blades can be used without problems. hard metal coatings.
nes, Inometa offers special composite coa-
tings with very good wear and chemical resis- Dryer Felt Rolls Spreader Rolls
tance characteristics. For the user, Flexocoat PROTEK non-stick coatings have proven to be Inometa offers various coatings for a wide
V170 and V12 plus mean a considerable in- best suited for dryer felt rolls, offering excel- range of applications. The solutions range
crease in service life when compared to lent anti-adhesion, corrosion resistance and from non-stick coatings for coating machines
rubber-coated rolls. traction properties. PROTEK ceramic coatings to hard metal coatings for excellent traction
can be particularly recommended if a doctor to extremely wear-resistant ceramic coatings.
Another alternative is the proven PROTEK blade is to be used.
non-stick coating which is used when bitu-
men, stickies, latices or similar substances Calender Rolls
escape, and using doctor blades is not possi- For calender rolls, Inometa offers the specially
ble for technical reasons. developed PROTEK hard metal coatings, which
have the distinction of a very high degree of
But when it comes to extreme wear resis- wear resistance, hardness and a very low de-
tance, dimensional stability and high degree gree of roughness (Ra < 0.03 m).
of hardness, PROTEK hard metal coatings
are the obvious choice. This coating has Reel Drums
hardness of up to 1,450 Hv, a surface rough- Ideally, features required for reel drums such
ness of Ra 0.03 m, and is resistant against as wear resistance, impact strength and
A CORNUCOPIA OF FUNCTIONS THAT WILL LEAVE YOU FAVORABLY IMPRESSED

CHARACTERISTICS

Non-Stick Properties Thermal Insulation Traction or sliding


Precisely adjusted hydrophilic/hydrophobic Electrical or thermal insulation and/or con- These properties can be specifically adjusted.
properties provide extremely durable function ductivity are properties that are required for The aim is e. g. to have prevent slippage,
surfaces, especially in conjunction with very example for corona surface treatment of films air intake or wrinkling of the web. The Euler
abrasion-resistant surface coatings. With the and paper. PROTEK surfaces achieve dielec- Eytelwein formula is used to determine the
help of additional micro- and/or nano-struc- tric strengths of > 30 kV. Thermal insulation friction value. Here, the static friction prop-
tures, very strong anti-adhesion properties coatings can e. g. be used in conveyer furn- erties between substrate and roll surface are
can be achieved which can be of advantage aces. High-performance thermal barrier coa- determined with the help of a defined angle
in areas where sticky substances are manu- tings have a thermal resistance value of up of contact.
factured and processed. to 1 Wm/K.

Adjustments
Protection against corrosion, abrasion and
erosion. PROTEK surfaces can be adapted
hydrophilic (water-friendly), contact angle towards 0 to precisely meet various industrial require-
F1 F2 spring scale
ments such as hardness, adhesion, cohesion
and porosity.

hydrophobic (water-hostile), contact angle at > 90


PRODUCTS AND SERVICES | 13

WITH EXPERIENCE AND COMMITMENT

PRODUCTS AND SERVICES


Inometa is dedicated to continuous product and process innovation so that our customers can maintain their technological
and economic edge. We develop and manufacture tailor-made coatings for industrial applications.

Inspection, Recoating and Repair environmentally responsible disposal of old In addition, you will enjoy the outstanding
Our services cover all work from regular coating material expertise Inometa can provide:
inspections to coating and repair: development of individual, customer- over 250 experienced, highly motivated
coatings can be applied to components friendly service plans employees in management, development
with dimensions of up to 2 m diameter, and production
17 m length and 20 t weight Roll Service decades of experience in roll technology
application-oriented and precise choice of Our services are offered for guide rolls, func- and roll coating for the most demanding
coating tional rolls, calender rolls and spreader rolls applications
recoating procedures on high-performance-/ of all manufacturers represented on the mar- years of experience in consulting, design
roll coating equipment ket. This has the following convincing advan- and calculation of spreader rolls for the
mechanical machining such as turning, tages for you as our customer: paper industry
grinding, brushing, lapping and polishing greatest possible reliability through exclu-
dynamic balancing acc. to VDI 2060, sive use of spare parts made by renowned
ISO 1940 manufacturers
damaged journal inspection and refurbish- processing of steel, aluminium and compos-
ing of damaged bearing seats ite materials with advanced manufacturing
customer-oriented coating development technology

High-performance lay-on roll made of CFRP with extremely wear-resistant PROTEK hard metal coating.
14 | SURFACE SPECIFICATIONS

ROUGHNESS DEPTHS AND SURFACE HARDNESSES

SURFACE SPECIFICATIONS
SURFACE PROFILE CORE SIZES EXPLANATORY NOTES

roughness profil (R profile) total height of the profile Rt The roughness profile is created through high pass filtering, i.e. through suppression
of long-wave profile components. The total height of the profile Rt is the sum of the
Zp

z
height of the largest profile peak Zp and the depth of the largest profile valley Zv within
the evaluation length ln.
Rt

x
lr
ln=5lr
Zv

Rp, Rv Height of largest profile peak Zp, depth of largest profile valley Zv within the
Zp3

z
sampling length lr.
Rz

x greatest height of profile Rz1 The greatest height of the profile Rz is the sum of the height of the largest profile peak Zp
Ra
Zp2=Rp

and the depth of the largest profile valley Zv within the sampling length lr.
Zp1

Zv2
Zv1

lr Rv=Zv3

x arithmetic mean value of the The arithmetic mean value of the profile ordinate values Ra is the arithmetic mean value
z profile carrying
curvek profile ordinate values Ra1 of the amounts of all ordinate values Z(x) within a sampling length lr.

material ratio of the profile Rmr The material ratio of the profile Rmr is calculated as the quotient of the sum of the load-
50
bearing lengths of material in the prescribed cutting height and of the measurement line.
ln 0 Rmr in % 100
centerline (x-axis) x The centerline (x-axis) x is the line which corresponds with the long-wave part of the
Z(x) height of profile at any position x; ordinate value profile which is suppressed by the profile filtering.
ln measurement line lr sampling lengthe

1
According to DIN EN ISO 4288, the arithmetic mean of five sampling lengths is generally used for core size determination for core sizes which are defined via sampling length. Source: Book of Tables (Europa Lehrmittel)

VICKERS HARDNESS HV10  ROCKWELL HARDNESS HRC MATERIALS POSSIBLE HARDNESS VALUES (HV0, 3)

400 41
500 48
metal 2001,000
600 55
700 60
800 64
ceramics 7001,300
940 68
1,000
1,100
carbide 1,0001,500
1,200
1,300
1,400
non-stick 2001,500
1,500
~ DIN 50150 rounded to whole numbers

ROUGHNESS RA VALUE RZ VALUE A layer optimized towards hardness will not automati-
cally have the high wear resistance required for the
N1 0.006 0.025 0.25 0.4
application. For economic reasons, the surface topo
N2 0.0251 0.05 0.41 0.63
graphy and the related surface roughness will be d2
N3 0.051 0.1 0.631 1
adapted to meet customer requirements.
N4 0.11 0.2 1.1 1.6
d1
N5 0.21 0.4 1.61 2.5
N6 0.41 0.8 2.51 4 (6.3) Vickers diamond test load F
N7 0.81 1.6 6.31 10
N8 1.61 3.2 10.1 25
N9 3.21 6.3 25.1 40
N10 6.31 12.5 40.1 63
substrate
N11 12.51 25 63.1 100
N12 25.1 50 100.1 160
Vickers hardness test Micro-Vickers test force Hv
~ following DIN ISO 1902
0.3 = 0.3 kg = 3N
INOMETA

INOMETA GmbH & Co. KG T +49(5221)777-0


Planckstrae 15 F +49(5221)777-500
32052 Herford info@inometa.de
Germany www.inometa.de

20/01/2014/en/