Osborn Roller Catalogue

umbruch_engl_deu:umbruch_deu 05.03.
2009 15:07 Uhr Seite 1
Innovative Solutions for

Metals Processing Technology
Brush Rolls
Equipment & Systems
Non-woven Rolls
Members of Jason Finishing Group

umbruch_engl_deu:umbruch_deu 05.03.2009 15:08 Uhr Seite 2
Mission statement
With the ability to connect global competence Reliability and sustainability in terms of our
in the best possible way for our customers customers, employees and company deter-
alongside the provision of local, extensive mine our actions. At the same time, the prin-
service, we develop and manufacture innova- ciple of responsible and careful management
tive, quality products and solutions targeted of our environment and its natural resources
for machine system engineering and opera- applies to us at all times.
tors of rolling mills and strip processing line
technology.
1
Content
1 Introduction Page 3
2 Brush roll applications
2.1 Degreasing, washing and cleaning Page 5
2.2 Activation of strip surface Page 7
2.3 Roll cleaning and polishing Page 8
2.4 Strip polishing and finishing Page 9
2.5 Scale removal Page 11
2.6 Roll coating control Page 13
2.7 Transport roll systems for HHT furnaces Page 15
2.8 Transport roll systems for high temp applications Page 17
2.9 Transport roll systems for noise reduction Page 18
3 Brush roll systems
3.1 Complete brush roll systems Page 19
3.2 Factory Assembly (FA) brush roll systems, Integrated Maintenance Service Page 21
3.3 Customer Assembly (CA) brush roll systems Page 23
3.4 OSBORN HDL® brush rolls Page 25
3.5 Lipprite® abrasive non woven rolls Page 27
4 NOVOTEX® non-woven rolls Page 29
5 Innovative equipment technology
5.1 Vacuum squeezing systems Page 35
5.2 Brushing equipment for strip processing lines Page 37
6 Load Runners® idler rollers and load rails Page 39
7 Fill materials Page 41
8 Technical data Page 43
9 Our further product range Page 45
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OSBORN International
1 Your competend partner in surface finishing solutions - worldwide
Companies all over the world rely on the quality and effi- close complex service network of the other OSBORN busi-
ciency of OSBORN. With a total of twelve sites, high quality nesses and branch offices or local service partners provide a
tools are developed and manufactured for processing sur- comprehensive service for our customers’ rollers anywhere
faces for use in a variety of branches in industry. in the world.
Specialised technology centres in our factories in Germany,

England, Sweden, the USA, Brazil and China as well as a
Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
Brush roll service centers
Europe OSBORN International GmbH America OSBORN International Ltda.

Ringstraße 10 Rua Lemos Torres, 150, Jardim Galiardi
35099 Burgwald - Germany 09890-070 Sao Bernado do Campo - Brazil
Phone: ++49 (64 51) 5 88-0 Phone: ++55 (11) 43 91 65 59
Fax: ++49 (64 51) 5 88-206 Fax: ++55 (11) 43 91 65 50
eMail: techsales@osborn.de eMail: brsales@osborn.com
OSBORN Unipol Ltd. OSBORN International

Lower Church Street 5401 Hamilton Avenue
Chepstow, Monmouthshire NP16 5XT - UK Cleveland, OH 44114-3997 - USA
Phone: ++44 (12 91) 63 40 00 Phone: ++1 (800) 720 33 58
Fax: ++44 (12 91) 63 40 98 Fax: ++1 (216) 361-1913
eMail: info@osborn.co.uk eMail: brushes@osborn.com
OSBORN International AB Asia Pacific OSBORN International China

(Sinjet Nässjo Borst) Rm. 505, Tower H, Huiyuan Int. Apartment
Huskvarnavägen 105 No. 8 Beichen East Road, Chaonyang District
S-56123 Huskvarna - Sweden Beijing 100101 - PR China
Phone: ++46 (36) 38 92 00 Phone: ++86 (10) 84 98 81 91
Fax: ++46 (36) 14 43 49 Fax: ++86 (10) 64 99 18 63
eMail: info@osborn.se eMail: cnsales@osborn.com
Further contact details worldwide: www.metallurgy-brush.com
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High-quality raw materials, years of experience, modern but we are not satisfied with that. Constant innovation and
manufacturing techniques and careful workmanship. These product development are of central importance to us, both in-
are important criteria which provide the consistently high house and in close cooperation with technology partners in
quality of OSBORN products. Quality assurance accompanies Europe, Asia and North America. We seize the incentive of
all stages of production. It is fully integrated into the process- making our range of services, and with it the products and
es and certified in accordance with DIN EN ISO 9001-2000. processes of our customers, better, faster, more reliable, safer
This has made us the world’s Number 1 in brush technology, and more environmentally friendly.
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Brush roll applications

2.1 Degreasing, washing and cleaning
The demands relating to the quality and the technical prod- in comparison to conventional brush rollers sets new stan-
uct characteristics of flat rolled steel in the form of cold dards in the degreasing and cleaning of strip surfaces.
rolled steel, tin plated steel, electrical steel, galvanized strips Through the consistent further development of the most
or other refined surface materials are steadily rising. Along important quality criteria (fill material, brush construction
with increasing processing speeds, the logical requirement and fill density) and at the same time by optimising the
for optimising the tempering, refinement or coating process using parameters, significant improvements can be
of the upstream strip cleaning section arises. achieved in terms of the brush lifetime / cleaning perform-
ance and with it, apart from the technically qualitative
With the development and introduction of the HDL® brush aspect, a reduction in operating and maintenance costs can
roller, OSBORN has found an answer to this problem, which also be realised.
Application category Metallurgic field Process line Description of application OSBORN product range
Carbon steel CGL, CAL, CL/ DL, ETL

Removal of oil, grease, other Brush rolls, abrasive or non-
Degreasing, washing Stainless steel CCL, CAPL, BAL, CL protective coatings, rolling abrasive, OSBORN HDL®
and cleaning Aluminium TLL, SL/ CCL residues or dirt from the Technology
strip/sheet surface
Non ferrous CL, DPL, APL, CPL
OSBORN HDL ® - a new benchmark in strip cleaning
Different demands are made on the brush depending on the OSBORN HDL® brush rollers are therefore individually tai-
type and degree of soiling of the primary material as well as lored to the relevant case in hand. At the same time, multi-fil-
the strip cleanliness required for the subsequent process aments and special mono-filaments can be used with or with-
step. While optimum degreasing and micro-cleaning can be out an abrasive portion as single bristle or mixture filaments.
achieved with non-abrasive multi-filaments, abrasive fila-
ments are ideally suited for the removal of strongly adhesive
rolling retentions from the previous rolling process.
5
Besides brush rollers for degreasing and cleaning applica-

tions, OSBORN offers a series of other innovative products
and solutions for cleaning sections of strip lines:
• LOAD RUNNERS® ensure a durable and maintenance-free

function of roll exchange vehicles.
• Temperature and alkaline resistant brush sealing provides

optimum splash protection on the strip inlet and outlet of
individual machine elements.
• Vacuum squeezing systems set new standards in the com-

plete drying of strip edges. It is possible to replace the hot
air dryer altogether and through this, ensure enormous
energy savings as well.
• In the modernisation of strip lines it is possible, through the

integration of optimised brush machines instead of the old
line, to create additional space for further improvements to
the line due to the compact design as well as an improve-
ment in cleaning efficiency.
• NOVOTEX® squeezing rollers complete the OSBORN strip

cleaning range. Compared to conventional rubber or
polyurethane rollers, these non-woven rolls offer a number
of beneficial product characteristics, such as significantly
better coefficients of friction, material compression or cut
and wear resistance, which in turn ensures longer durabili-
ty, improved squeezing results, the prevention of aquaplan-
ing and the reduction of damage to the strip.
OSBORN innovations for cleaning sections in strip processing lines
Alkaline brush Squeezing Brush cleaning Squeezing Squeezing

cleaning rolls rolls rolls
OSBORN HDL® NOVOTEX® OSBORN HDL® NOVOTEX® NOVOTEX®
Load Runners® Brush sealings
Alkaline spray Electrolytic Water rinsing Hot air dryer

cleaning cleaning
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2.2 Activation of strip surface
The activation of the strip surface is an important task both in In the next process step, an activation of surfaces then takes
the production of rolled claddings as well as in the coating place by generating a defined roughness using abrasive or
and/or finishing of strip steel, tinplate, electrical steel strip wire brushes. A similar process also happens in continuous
and other materials. In rolled cladding, the core and, if neces- strip coating. In both cases, an optimal adhesion is guaran-
sary, the overlay strips or plates have to be freed initially from teed for the subsequent rolled cladding and/or organic or
oil, grease, dirt, carbon particles and oxides with the help of metallic coating through surface activation.
brush rollers in alkaline cleaning or acidic pickling processes.
Strip surface activation

Carbon steel CGL, CCL, EGL, ETL
prior to coating Brush rolls, abrasive or wire-
Activation of strip surface Strip, sheet or plate surface filled, OSBORN HDL®
Aluminium CM
preparation prior to cladding, Technology
Non ferrous APL, CPL coating or pressing
OSBORN HDL ® - micro cleaning plus surface activation
Here too, HDL® rollers from OSBORN create an ideal combi- This is a challenge that OSBORN has set itself for years and
nation of the different brush functions which are required. The through which we have worked out a technological advan-
non-abrasive multi-filaments ensure optimum micro-cleaning tage for ourselves in the production of brush rollers with the
as the abrasive filament mechanically intensifies this through development of innovative microfilaments and brush con-
its abrasive effect and at the same time, generates the surface structions as well as even higher quality standards.
activation which is required. The grinding agent, grain size,
facing density and abrasive portion are also individually
adjusted to the respective individual application.
In steel sheet coating, the brush roller has long been promot-
ed as an absolute high-performance and precision tool in the
case of thicknesses of <0.15mm, coating thicknesses of 0.05g
/ m² and ever higher line speeds. At the same time, the indi-
vidual demands made on the brush can be quite different
depending on the flatness, surface hardness of the starting
material and the nature of the subsequent coating or plating.
7

Roll cleaning and polishing 2.3
For cleaning work and back-up rolls in wet or dry operated neutrally ground at the radius and axially and either gains a
rolling and skin-pass mills, OSBORN’s Helimaster brush cylindrical camber ground, or for offsetting the computed roll
rollers have characterised worldwide technological develop- deflection, a positive and/or negative camber ground.
ment for decades, both in online lines integrated in strip lines
as well as stand-alone off-line rolling stands. In the meantime, with Lipprite® abrasive rollers, an alternative
technology has also been developed and manufactured in-
In doing so, the rollers can work sporadically or continuous- house for skin-pass roller cleaning.
ly, designed as a wire or an abrasive brush. Each brush is
Carbon steel SPM,TM, CGL Helimaster® Brush rolls, abr-

Removal of oxides, dirt sive or wire-filled; Non-abra-
Roll cleaning and polishing Stainless steel SPM,TM
and rolling residuals sive Brush rolls; Lipprite®
Aluminium CRM abrasive non-woven rolls
The brush roller itself is only part of

the solution. This is because this technically
demanding application can ultimately only be opti-
mally implemented by a precise matching of the brush tool
with operational and process parameters. The reproducibility
of the specified corrosiveness and brush effect plays an
important role as well as constant tool performance from the
first point of use to the exchanging of the roller. Roll cleaning appliaction in a typical skin-pass mill
For the cleaning of deflector, shape control or thickness meas-

urement rolls, special wear-resistant non-abrasive plastic fila-
ments are used. They ensure an equally thorough removal of
solids and liquid materials without damaging the roll surface
or altering the roughness. At the same time, the filament type
and bristle diameter are dependent on the surface hardness
and the degree of soiling of the roll to be cleaned.
8

2.4 Strip polishing and finishing
When it comes to the optical finishing of strip surfaces in Apart from high-quality wire and abrasive brushes, we can
the form of polishing, sanitising, finishing or decorative at the same time rely on the merger with the Lippert-Unipol
grinding and brushing, you’re in good hands with OSBORN. Group, one of the global leaders in abrasive and polishing
Decades of experience in the machining of steel, stainless tools, using polishing and abrasive rollers and polishing
steel, aluminium or other non-ferrous surfaces have given pastes on a selection and combination of tools and pro-
us a technological advantage, from which today our cus- cessing alternatives, which is unique in the market. Use this
tomers benfit worldwide. advantage to optimise your process - for perfect surface fin-
ishing.
Oxide removal, polishing Brush rolls abrasive or wire-
Carbon steel
and finishing of hardened filled; Bessemer-wire brush
Strip polishing and finishing Stainless steel and tempered strips rolls; OSBORN HDL®
PL, APL , FL
Aluminium Oxide removal, polishing, Technology; Lipprite® abrasi-
finishing and generating ve non-woven rolls; UNIPOL®
Non ferrous
decorative surfaces polishing emulsion
Today, increasingly higher demands are made on the final

machining of strips. Apart from an optically perfect and per-
fectly homogeneous surface over an entire field of vision, the
correction of small surface defects in the last mechanical
machining step is demanded at the same time. This applies
equally to the operators of strip lines as well as for service
centres or the direct processors of coils.
Different types of rollers and coatings can also be used

depending on the material type and quality, the surface hard-
ness and the required finish and condition before the final fin-
ishing. For determining the respective optimum tool, we
carry out individual pilot tests at test lines in our laboratory.
9
A combination of Bessemer wire roller brushes and polishing

emulsions are used in the removal of oxide layers and pol-
ishing cold rolled uncovered strips after annealing re-crys-
tallisation. At the same time, both components come from
OSBORN-UNIPOL and are specifically coordinated to the indi-
vidual surface requirements.
All-in-one solution made by OSBORN-UNIPOL
Polishing station with

Bessemer wire brush rolls
UNIPOL® polishing emulsion

(liquid emulsion application)
UNIPOL® polishing emulsions are initially directly applied to Our Lipprite® product series represents an alternative to
the strip surface to be processed as a liquid paste in immer- brush rollers with a wire or abrasive bristle coating, as with
sion baths or by means of a low-pressure, medium-pressure, grinding non-woven rollers, an absolutely uniformed fine
high-pressure or airless spraying system. final grind and a corresponding homogeneous surface finish
With Bessemer wire measuring diameters of 0.06 or 0.08 can be achieved. With the correct contact pressure, the flexi-
mm, filled rollers serve as carriers of this paste in the subse- ble roller surface is in a position similar to a brush, to offset
quent polishing process. any slight unevenness of the strip.
Lipprite® abrasive non woven rolls - for a perfect surface finish
10

2.5 Scale removal
In de-scaling strip surfaces after the hot and cold mill process, been possible to achieve tremendous quality and improve-
our brush rollers have been setting standards in strip lines for ments relating to service life on numerous strip lines and with
years. OSBORN’s developments and innovations both on the it, a substantial reduction in the total cost. The parallel opti-
part of brush construction as well as filaments have in the misation of the brush / shaft design and operational parame-
meantime set the international standards in annealing and ters through targeted assistance on site with the customer is
pickling lines or bright annealing lines for stainless steel strip. another important OSBORN competence based on our long-
standing worldwide experience. Set us a challenge!
With the development of acid resistant fill materials it has
Carbon steel CPL Heavy duty descaling prior Brush rolls abrasive or wire-
HAPL to acid pickling filled; Heavy abrasive brush
Scale removal Stainless steel rolls; OSBORN HDL®
HAPL Heavy duty descaling between acid tanks Technology; Lipprite® abrasi-
Non ferrous HRM Scale and dirt removal prior to rolling ve non-woven rolls
A new brush-generation - acid proof filaments
Through the development of special abrasive and non-abra- out of acid or other corrosive media from the brush lining. On
sive facing materials combined with a much improved level the one hand, an optimum rinse function is ensured by the
of acid resistance and with that good wearing properties, the correct number and size of the cooling holes and the other by
lifetime of brush rollers in stainless steel strip lines has now the correct choice concerning the quantity of liquid.
been significantly increased. This allows tremendous cost
savings in the form of longer lifetimes and lower mainte- At the downstream strip drying operation, similarly signifi-
nance costs. cant process improvements and substantial cost savings can
be achieved through squeezing rollers using newly devel-
Ideally, the abrasive rollers are inserted on roller systems oped acid-resistant non-woven materials as well as vacuum
made from hollow shafts with bore holes. Apart from systems.
improved cooling of the filaments in the continuous opera-
tion of the roller, these also provide the continuous rinsing
11
Where stainless steel materials reach their limits in high acid

concentrations, special protective coatings on shafts and
accessories secure the optimal protection of these compo-
nents.
In addition, for cost reasons steel shafts with shock and
impact resistant coatings have come to represent an interest-
ing alternative to stainless steel bodies.
In manufacturing stainless steel flat products, OSBORN • NOVOTEX® squeezing rollers with an acid resistant non-
International’s intelligent solutions and innovations play a woven covering
part in process optimisation and quality improvement as well
as being deployed for de-scaling hot and cold mill strip sur- • Helimaster brush rollers for cleaning rolls in skin pass mills
faces at many other levels of the value chain:
• Vacuum squeezing roll systems as an energy saving replace-
• HDL® brush rollers with a micro-fibre brush for careful and ment strip dryer
thorough cleaning of sensitive strip surfaces
• High temperature brush transport rolls for hot and cold strip
• Acid and temperature resistant brush sealings on continuous furnace lines
• Lipprite® abrasive rollers for surface finishing and follow-up • Brush transportation rolls for reducing noise on slitting and
processing plates and strips cross-cutting lines for heavy plates
• Braking, tension, deflection or pressure rollers made from a • LOAD RUNNERS® heavy load rolls in coil transportation
non-woven covering for replacing rubber or polyure- devices or roll exchange vehicles.
thane rollers
Process chain of stainless steel flat products manufacturing
Steel mill Hot rolling mill Pickling line Cold rolling mill Anealing and pickling line
Anealing and pickling line Bright anealing line
Stretch levelling line Stretch levelling line
Slitting line Cross cutting line
Hot strip Cold strip

Slab Wide strip Wide strip Slit coil Blanks Wide strip Slit coil Blanks
12

2.6 Roll coating control
Almost 50 years ago, OSBORN developed a revolutionary ities, abrasive multi-filaments, individually camber ground
technology using brushes in the continuous rolling process surfaces and extensive experience in optimising the use of
in order to optimally regulate the oxide film on working and brushes in numerous individual applications have secured
back-up rollers in hot rolling mills. Meanwhile, hundreds of a big technological advantage for us in this field, from
rolling hot mills worldwide have been equipped with which our customers benefit worldwide.
OSBORN technology. To date, specially designed wire qual-
Aluminium HRM, HRFM, HFM Control of the oxide layer Helimaster® Brush rolls
Roll coating control
Non ferrous HCM and removal of oxides abrasive or wire-filled
Lateral rings made of composite fibre materials for limiting On hard chrome working rollers, abrasive multi-filaments
immersion depth and sleeves for splash guarding journals with a high density achieve a particularly uniform brushing
and bearings - developments created by OSBORN. and cleaning of the roll surfaces.
13
The individually adapted camber ground of the brush roller brushed, and the calculation of the optimum crown is car-
body is one of the most important prerequisites for ensur- ried out. OSBORN of course also grinds brush rollers with
ing uniform brushing across the entire width of the roll. a CVC contour on CVC technology mills for roller gap
Convex or concave contours are ground, depending on the adjustment.
construction of the working or back-up rollers to be
Precision camber ground - for optimum brushing results
14

2.7 Transport roll systems for HHT furnaces
The tempering of hot mill plates made of precipitation hard- of up to 600°C on brushed transportation rolls. In close coop-
ening aluminium alloys through the process of solution eration with leading equipment manufacturers, numerous
annealing serves the purpose of attaining higher strength and furnaces around the world have been equipped in recent
strain values along with a good level of corrosion resistance years with OSBORN’s sophisticated technology. In the
for the material. Today, this is required for structural parts in process, plates with thicknesses of up to 400mm, lengths of
aircraft in accordance with the high requirements of stan- 20 metres and weights of over 10 tonnes do not represent a
dards AMS 2750D, AMS 2750C and AMS-H-6088. problem for us. Tolerances have been continually reduced
The careful transportation of these aluminium plates in ‘hard and product features optimised, so that now more than ever,
metal and hard material technology’ roll hearth furnaces the brush roller is an important and technically superior com-
takes place as a batch or reversing process at temperatures ponent in the overall design of the line.
Transportation of hot plates

Brush transport rolls; HHT
Transport roll systems for throu the heat treatment pro-
Aluminium HHT plate furnaces cess; optimized heat transfer; brush transport roll systems;
HHT furnaces Furnace capacity increase
Avoidance of transport roll pick-
concepts
up and surface damages
Surface-sparing plate tracking with longstanding roll lifetimes
With brushed furnace transportation rolls, OSBORN cus- For roll assemblies in new furnace lines, this allows OSBORN
tomers can today place their trust in several decades of expe- to guarantee an optimum course of the sheet within tight tol-
rience and well known global references. In the complex pro- erances even when starting up the run.
duction of the rolls, some with a total length of over 6000mm
and 4000mm of brushed length, the highest levels of preci- In order to guarantee the lowest possible of amount of sheet
sion and reliability are required in all manufacturing process- tracking, with the ‘re-brushing’ of entire furnace zones, the
es. transportation of the sheets is simulated on an in-house test
After the rolls have been manufactured, the later course of rig just like new lines.
the sheet is accurately simulated in advance in our factory.
15
This advanced technology provides convincing arguments as

to why brushing using heat resistant wires is increasingly
establishing itself as a roller cover for furnace transportation
rolls.
• Optimum heat transfer between the transportation roll and

the plate
• Lifetimes of several decades without significant wear of

the brushes
• Complete avoidance of scale pick-up and spot formation

on the surface of the roller, just as is mostly the case
with self-contained roller coverings
• Total-care transportation of the plates during the heat treat-

ment without damaging the surfaces of the plates
Apart from the production of new rolls, the recovering and

replacement of worn brushes in older lines is also one of our
core competences.
By precisely measuring the course of the plate as well as the

state of the individual rolls within the furnace by means of
self-developed test equipment, we are able to optimise plate
tracking if needed and through this, to optimise the output of
the entire system.
Capacity optimization at older furnace installations

Plate tracking in initial state
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
Plate tracking after optimization as per OSBORN recommendation
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
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2.8 Transport roll systems for high temp applications
Roll coverings made from extremely dense stainless steel rollers with ceramic coatings. These can be used in different
wires in special alloys which are resistant to high tempera- horizontal heat treatment lines for strips of steel, stainless
tures provide specific product features and strong advan- steel or nonferrous metals.
tages compared to uncoated transportation shafts or furnace
Carbon steel CAL, CGL

Transport roll systems Stainless steel BAL,CAPL,CAL,HAPL Transportation of high temp strip; High temp brush transport
for high temp Avoidance of transport roll pick-up rolls; Brush transport roll
applications Aluminium and surface damages systems
HHT
non ferrous Bandofenanlagen
Excellent brush lifetimes without scale pick-up - up to 1100°C
Properties and Advatages • As a result: Particularly careful transportation of the plates

and reduction of damage to the surface
• Temperature resistance of up to approx. 1100°C
• Very low wear to the rolls with significantly longer lifespan
• Shaft construction with internal cooling than ceramic coatings or other roll coatings (in comparison)
• Extremely dense and accurate neutrally ground surface of

the rolls
• Significantly better heat transfer characteristics of the tips of

the wires when compared to surfaces made up wholly of
material
• No scale pick up (formation of spots) on account of the

absorption properties of the exposed brush surface
• As a result: Reduced maintenance
17

Transport roll systems for noise reduction 2.9
When transporting the sheets onto rolling tables, extreme By coating the bright transport rollers with brush sections,
noise levels may occur in slitting/cross cutting lines for heavy the noise level can be reduced to around 70 dB so that a risk
plates after the shearing process. At over 110 dB, this may to health in terms of occupational health and safety is signif-
possibly exceed the threshold of noise pain for the human icantly reduced.
ear.
Carbon steel
Transport roll systems Stainless steel Low noise surface friendly Noise-reduction transport
SL, CCL transport
for noise reduction transportation of plates or rolls; Noise-reduction
Aluminium roll tables
sheets transport roll systems
Non ferrous
All in all, our brushed transportation rolls offer a number of

advantages for the user through their positive product fea-
tures:
• Significant noise reduction in transporting sheets > 30%
• As a result: improved and safer working conditions
• An overview is achieved with regard to purchasing costs
through the equipping of existing shafts with brush car
tridges in sections
• Less wear of the heavy wire brush roll surface
• As a result: roll service lives of up to 10 years
• Particularly careful transportation of the sheet surface
• No soiling of the roll surface through the absorption of dirt
into the brush lining
• As a result: Reduction of maintenance costs for the rolling
table
Pain threshold Obligation of ear protection
Noise level reduction

from 110 dB to 70 dB
with OSBORN transport rolls
120 dB 110 dB 100 dB 90 dB 80 dB 70 dB 60 dB
18
Brush roll systems

3.1 Complete brush roll systems
Through many years of cooperative development work with around the globe in all stages of project development, from
machinery manufacturers in the design of rolls and brushing the initial design to commissioning. A whole host of well-
machines as well as with the operators concerning produc- known manufacturers in the business of strip and heat treat-
tion line and process optimization, OSBORN has an estab- ment plants and rolling mill technology benefit from this
lished wealth of experience in this field. Through our world- expertise which ultimately rewards the plant operator in the
wide sales and service network we are able to guarantee form of well-engineered products and innovative technolo-
comprehensive technical support for new production lines gies.
Product group OSBORN product range
Shafts for brush rolls
Brush roll fillings
Re-usable tube bodies
Shafts for back-up rolls and other roll types

Complete brush roll systems Balancing collars
Bearings and Complete bearing units
Splash rings
Other fittings and accessories
Transport boxes and packaging concepts
Apart from the manufacturing of complete brush rollers with

different shafts and body constructions, our range of services
also includes the bearing units, splash rings and accessories.
In addition, we also manufacture and supply shafts and com-

plete systems for other roll types used in strip line systems.
These come without or, on request, with hard chrome,
polyurethane, rubber or other special coatings.
Customized solutions for equipment manufacturers
19
Lateral balancing rings with trapezium grooves and sliding

balancing weights serve to dynamically balance the shafts
from grades G 1 to G 6.3 in accordance with DIN EN ISO
1940. With certain material grades it is a good idea to pitch
the balancing nut in order to ensure simple disassembly.
The construction of bodies with hollow shafts suitable for

internal cooling is primarily used in abrasive brushes for
heavy-duty applications. Apart from improved brush cooling
with greater frictional heat when used in corrosive media,
they continuously and uniformly rinse the brush in operation
from the inside out by means of the centrifugal force, which
leads to an improvement in the brush’s lifetime.
20
Brush roll systems

3.2 Factory Assembly (FA) brush roll systems
At OSBORN, decades of global expertise is consistently com- OSBORN factories or local partners spread over many coun-
bined with a local, comprehensive all-round service package tries offer a comprehensive service for your rollers. This
on the customer’s premises. In addition to six centralised allows customers around the globe to directly benefit from
technology centres in Asia, Europe and North and South our technology and the comprehensive range of services on-
America, the other service centres belonging to the various site.
Brush roll re-filling (SPW/NB)
Integrated maintenance service concepts
Re-trimming and re-balancing of brush rolls
Shafts and journal control and repairing
Factory Assembly (FA) Bearing control and exchange

brush roll systems
Shaft improvement/adaptation
Integrated maintenance service Shaft straightening
Stress free annealing of shafts
Replacement of end and balancing collars
Replacement of fittings and accessories
Transport and packaging concepts
Supply of brush roll trimming equipment
An extensive transportation network, partly with company-

owned vehicles, provides a quick and easy collection and
return service for customer rollers.
Apart from the direct re-brushing of customers’ shafts or the

on-site assembly of brush cassettes, our comprehensive
range of services includes all worthwhile and necessary
inspections as well as repair and service work relating to our
customer’s rollers.
We combine global know-how with local full service
21
Upon receipt by our service centre, each roller immediately

undergoes a professional inspection in accordance with the
extent of the agreed service contract. The condition as well as
the time and expense involved with the maintenance are doc-
umented with the aid of standardised protocols.
The quiet and low-vibration running of the rollers is impor-

tant in order to avoid shatter marks or shading on the strip
surface caused by the brush roller. Before recovering, each
shaft is therefore examined with regard to inbalance and con-
centricity deviation, in order to align it straight away if neces-
sary and to rebalance it.
The longer the service life of rollers, the more important is a

proper condition of the bearings for avoiding additional
downtime or outages. For this reason, bearing units are
checked and maintained by us. If necessary, the bearing unit
or other accessories are renewed.
Conditioning
Worn bearing seats are welded and precisely re-machined to

the original specification.
Following this, immediate re-brushing or the assembly of

previously prefabricated brush cassettes takes place.
Reworking
22
Brush roll systems

3.3 Customer Assembly (CA) brush roll systems
OSBORN has the right solution for customers who want to different shaft that a customer has, like no other manufactur-
recover and maintain their brushes in-house – roller systems er in the world.
for self-assembly. Our range of products and services
includes cassettes in fully-automatic internally-welded spiral At the same time all of the usual filaments, wires or natural
constructions, disk constructions as well as constructions bristles can be processed and realised according to individual
assembled on one-way tube bodies and older structures with requirements at different trim lengths and densities - from
single discs or loose spirals. In order to individually adapt light to standard, to extremely dense.
these to existing shaft constructions, they are additionally
provided with one-way adapters, if required. We also provide the right equipment for simple follow-up
As such, we can supply the right cartridge for almost every shearing of the roller on a lathe.
Cassete brush rolls - spiral type (SPW/IV)
Cassette brush rolls - disk type
Customer Assembly (CA) Brush rolls - one-way tube construction (SPW/RK)

brush roll systems Hotani® Cassete brush rolls
Single brush disks
Loose spiral coils (SPW/LS)
Intelligent and well-engineered roll constructions without

complicated clamping systems make the simple and fast,
immediate exchanging of brush coverings on the spot a
breeze.
OSBORN brush cassettes are trimmed in sets. Each individual

segment is labelled and marked in accordance with the
assembly instructions. This ensures simple and complete
assembly without diameter variations.
Cassette systems for simple self-assembly onto customers’ shaft
23
With modern shaft constructions from OSBORN it is possible

to dispense with balancing the shafts.
Precision manufactured inner diameters, in narrow tolerance

ranges ensure that the individual cassettes optimally sit on
the on the shaft and prevent vibrations when running.
24
Brush roll systems

3.4 OSBORN HDL® brush rolls
OSBORN International once again sets a new benchmark in properties. In addition, the expertise from years of close
brush technology with HDL® brush rollers - the latest devel- cooperation with technology partners and line manufacturers
opment from us. By combining streamlined brush construc- in Japan, Europe and the United States as well as from the
tion with specially developed micro fibre fill materials, it has ever increasing demands on line operators has been brought
been possible to realise and successfully introduce a product together.
with significantly improved performance levels and wear
Microfibre/multifilament high-density brush rolls, abrasive or non-abrasive
Individual concepts improved brushing application in process lines (lifetime and brush performance)
Complete brush roll systems

OSBORN HDL® brush rolls
Factory Assembly (FA) brush roll systems
Customer Assembly (CA) brush roll systems
Adaption/improvement of existing rolls/Shafts
OSBORN HDL® - the benchmark in lifetime and brush performance
OSBORN HDL® conceals even more than this. What we mean individual covering is defined for the roller which is made
by this is an optimisation approach to strip lines with regard from non-abrasive and/or abrasive micro fibres and monofil-
to the various brush applications as well as the usage param- aments. In parallel, the shaft construction is optimised and
eters of these rollers. adjusted. In general, the customers’ existing shafts can be
used. In addition, the usage parameters of the respective
Initially, the current weaknesses will be analysed. Depending brush rollers are evaluated with regard to cooling, in-feed and
on the type of line and degree to which the brushes are revolution speed and an individual optimisation recommen-
required for cleaning, degreasing and surface activation, an dation is drawn up.
25
Compared to conventional standard brushes, OSBORN HDL®

Micro filaments improve strip cleanliness
rollers offer decisive advantages:
• Significantly increased lifetimes and reduced operating,

maintenance and overall brush costs
• Improved cleanliness levels in strip cleaning make a contri-

bution to quality improvements, process optimisation and
increases in line speed
• The targeted and better control of the rollers due to the

compact design with higher density makes a significant
contribution to reliability and controlled process control
Unlike conventional mono-filaments with bristle diameters

ranging between 0.15 and 1.5 mm our Novofil micro-fibre Due to the extremely high density and the individual mix with
material can also reach, in a targeted way, the rough depths new, especially hard and rigid abrasive materials, heavy soil-
of strip surfaces to be brushed due to their very thin thread ing and coarse metallic rolling retentions are removed in a
thicknesses of up to 0.02 mm, which brings with it signifi- way which is better than ever before.
cantly improved cleaning and degreasing levels. In the
process, a multi-filament bristle can be made from several
hundred micro fibres.
26
Brush roll systems

3.5 Lipprite® abrasive non-woven rolls
Through the merger of the corporate groups OSBORN In the process, Lipprite® abrasive rollers represent an alterna-
International and Lippert-Unipol, we have been able to signif- tive to brush rollers in various applications. Besides finishing
icantly expand our range in the field of rollers for achieving a applications, they are used for working roll cleaning, for sur-
technical or optical surface finishing. face activation, as well as for de-scaling.
Lipprite® - the abrasive alternative for a perfect surface
Overview of the roller coverings and material specifications for Lipprite® abrasive rollers
Aluminium oxide abrasive grain (AI2 O3) Silicon carbide abrasive (SiC)
A1 extra coarse XCRS Grain 36 S4 medium MED Grain 100

A2 coarse CRS Grain 80 S6 fine FN Grain 180 (240)
A4 medium MED Grain 100 S7 very fine VFN Grain 280 (320)
A6 fine FN Grain 180 (240) S8 super fine SFN Grain 500
A7 very fine VFN Grain 280 (320) S9 ultra fine UFN Grain 800
S10 micro fine MFN Grain 1500
Different hardness specifications for Lipprite®
Additional Lipprite® impregnation for increase lifetime and
103 - soft roller corrosiveness
105 - medium
107 - hard PH 90 Standard hard impregnation
109 - very hard PH 120 extra hard
The processing results achieved by Lipprite® abrasive rollers Based on many years of experience or by individual tests on
may vary a lot depending on the roller specifications, surface our test lines, we are able to specify the right product in a tar-
and individual usage parameters. For orientation, the follow- geted way for almost any surface roughness required.
ing approximate values for the achievable surface roughness Contact our application engineers.
(Rt) are:
• A4 (coarse) = 3.3 - 3.9 mm
• A6 (fine) = 2.9 - 3.6 mm
• A7 (very fine) = 1.1 - 1.8 mm
27
Lipprite® abrasive rollers are manu- Technical data and product characteristics:
factured from abrasive non-woven
flaps through radial adhesion to a • max. roller width 2000mm
core. The abrasive grinding grain • max. roller diameter 450mm
made of silicon carbide (SiC) or alu- • Version available with or without impregnation
minium oxide (Al2O3) is at the same • Rollers are dynamically balanced in accordance with DIN
time, embedded into the surface of EN ISO 1940
the random web fibre non-woven
material (made of polyamide or other synthetic material) by Recommendations concerning the use of rollers:
means of resin. The corrosiveness of the roller is individually
determined by the density of the pressure, i.e. the number of • Use in wet or dry operations
flaps. • Optimum cutting speed 15-25m/s
• Line (strip) speed or feed speed up to 30m/min. (max.)
An optional additional impregnation makes the roller even • Processing in the opposite direction to the running direction
more corrosive and increases the lifetime. It is necessary to of the material feed
bear in mind, however, that because of the significantly • Optimum depth of immersion 2-6mm, depending on the
increased hardness, impregnated rollers are less flexible. As roller diameter and hardness
such, surface undulations can be harder to balance, which • Oscillation improves the uniformity of the machining profile
may result in a less uniform finish or in terms of the machin-
ing profile, visual shading.
28
NOVOTEX ® non-woven rolls

4 Products and applications
Strip lines and rolling mills are equipped with a large number In parallel, through close cooperation with one of the world’s
of different rolls for completely different tasks and applica- leading manufacturers of technical non-woven materials,
tions. Through ever-higher line speeds and steadily increasing OSBORN has managed to develop a well-engineered series
demands in terms of quality and process reliability, the of products under the NOVOTEX® brand name, which are able
demands made on roll covers and surfaces also increases. As to fully satisfy the consumer’s expectations in terms of quali-
such, non-woven rollers, with their special material proper- ty, reliability, durability and an excellent price/performance
ties, become increasingly important within the steel, alumini- ratio.
um and non-ferrous metal industry.
NOVOTEX® - convincing in quality and profitability
Material properties and technical benefits
OSBORN’s NOVOTEX® rollers are used where other synthetic • It is significantly easier to avoid aquaplaning effects
roller coatings reach their limits and can no longer ensure
optimum results or stable processes, as compared to rubber • Through the applied pressure of the random web with high
or polyurethane, non-woven material offers crucial advan- pressure on a roller core, a roll coating arises which, with a
tages. hardness of up to 95 shore A, exhibits an enormous resist-
ance to being cut as well as a ‘self-healing’ effect in the
• The porous structure of non-woven fabric in combination event of light cuts
with a large pore volume makes the material compressible
• The capillary or suction effect when discharging the non-

woven structure provides a significantly lower amount of
residual moisture in squeezing applications
• In contrast to elastic, but hardly compressible rubber or

polyurethane coatings, a significant adhesion effect occurs
in the contact area for the strip surface which is under pres-
sure. Taking these roll coverings into consideration, this is
something that leads to significantly higher and more con-
stant coefficients of friction. 1 mm 1 µm
29
• This results in excellent wear characteristics with a much

higher roll lifespan in comparison to rubber or polyure-
thane
• Due to its pore volume, the roller covering is in the posi-

tion to absorb small particles of dirt, oil or grease residue
as well as light roller tinsel
• For a sustained period, the surface itself remains largely

free of contamination or hardened material - an important
criterion for permanent, reliable roll operation without fluc-
tuations in quality
• In addition, the strip surfaces are particularly conserved

and protected from damage
Economic benefits
The material properties and technical benefits described

bring about a series of economic benefits, which makes the
use of non-woven fabric rolls an interesting proposition from
a cost/benefit point of view:
Material compressibility of non woven
• Despite significantly higher acquisition costs for the individ-
ual rolls, the much longer service life ensures a reduction in
operating costs on balance
• Significantly longer lifetspans for the rolls reduce downtime

and as such, reduce maintenance costs Compression Expansion
• Even with the aid of the non-woven roll, quality and process
improvements gained in manufacturing operations con- NOVOTEX® non-woven roll Conventional rubber roll
tribute to an increase in economic efficiency
Friction coefficient as a feature of the oil film for solvent based liquids
0,30
0,25
0,20
Friction coefficient
0,15
0,10
0,05
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
Area weight of oil film (g/m2)
30
Product range
Apart from non-woven fabric coverings our range of products shaft accessories. Users can benefit from our maintenance
includes the production of shafts as well as the recovering of service which includes the examination and repair of dam-
worn out rolls. We offer complete package systems specifical- aged rolls as well as accessory parts.
ly for the construction of lines including bearing units and
Product group OSBORN Product range
Non-woven coverings and re-coverings
Shafts for non-woven rolls
Complete rolls incl. shafts and bearing units
Integrated maintenance service concepts
NOVOTEX® Re-trimming and re-balancing of used rolls

non-woven rolls
Partial repair of damaged roll coverings
Shaft and journal control and repairing
Bearing control and exchange
Replacement of fittings and accessories
Transport boxes and packaging concepts
31
Materials
When selecting the optimum non-woven fabric for the indi- Through the new development of the NOVOTEX® 12 covering
vidual application we can rely on the various material quali- material based on polypropylene, we have now also covered
ties which have been tried and tested and continuously squeezing applications in acidic cleaning and/or pickling sta-
improved over the years and which can be easily distin- tions using non-woven material.
guished by different colours.
OSBORN NOVOTEX® non-woven material range
Material type NOVOTEX® 09 NOVOTEX® 10 NOVOTEX® 11 NOVOTEX® 12
Colour Brown Pink Orange Grey
Technical data
Basic fibre PA PA PA PP
Range of hardness 90-94 shore A 70-85 shore A 90-95 shore A 70-80 shore A
max. operating temperatures 100°C 100°C 130°C 80°C

max. line loading at 50 N/mm 20 N/mm 100 N/mm 15 N/mm
<~200 m/min. line speed
max. line loading at 30 N/mm 10 N/mm 80 N/mm 10 N/mm
>~200 m/min. line speed
max. line loading at 20 N/mm --- 50 N/mm ---
>~300 m/min. line speed
Application data
Applicable for liquid categories oil and emulsions oil and emulsions oil and emulsions acids, alkalines
water water solvents oil and emulsions
squezzing, pinching squezzing squezzing, driving squezzing
main applications breaking
Camber ground
The roll deflection is of crucial importance for an optimum For this reason, OSBORN International defines the optimal
and uniform squeezing result over the entire width of the feed force for each non-woven roll and on this basis, works
strip. This is especially the case in weak or undersized shaft out the expected roller deflection. The roll balling will be
constructions. When the feed is too high the roll ‘whips’ lead- ground to exhibit convex or concave contours.
ing to excessive residual moisture in the central area, while
too little feed force causes wet edges or border areas.
Force
Bending X/Y - level
Too low force:

wet edges
Too high force:
wet centre
To specification:
uniform break
32
OSBORN Innovations for cleaning sections in strip processing lines
Alkaline brush Squeezing rolls Brush Squeezing Squeezing

cleaning cleaning rolls rolls
OSBORN HDL® NOVOTEX® OSBORN HDL® NOVOTEX® NOVOTEX®
Load Runners® Brush sealings
Alkaline spry electrolytic Water rinsing Hot Air dryer

cleaning cleanining
Besides NOVOTEX® non-woven rollers, the OSBORN range

includes more innovative products for cleaning sections in
strip lines, such as HDL® brush rollers, Load Runners® and
innovative equipment technology.
Brush sealing units which come in temperature, alkaline or

acid-resistant versions for sealing strip inlets and strip outlets
on line components, complete our range.
Applications
Non-woven rolls can be used in all strip lines or rolling mills

for steel, stainless steel, aluminium and non-ferrous metals,
e.g.
• Hot-dip galvanizing lines

• Continuous annealing lines
• Annealing and pickling lines
• Cold rolling mills
• Skin-pass mills
• Colour and/or organic coating systems
• Electrolytic galvanizing lines
• Cleaning or degreasing lines
and a whole range of other types of line. They also signifi-

cantly contribute to improving product and process quality.
33
When used as bridle rolls, tension rolls, steering rolls or

Applications
deflector rolls the advantages of non-woven fabrics over
Pressure rolls other synthetic coatings are especially clear. In a dry state and
especially in a wet state, a non-woven fabric has an excellent
and, above all, constant friction coefficient, both on oil as well
as on watery media. The friction coefficients of rubber or
polyurethane-coated rollers however, are very low; some-
thing which can easily lead to aquaplaning in the case of non-
driven roller, i.e. a floating of the roller, resulting in strip slip-
page and through this, scratches and damage to the surface.
S-rolls / Tension rolls /
On the other hand, non-woven coatings adhere well to the
Bridle rolls
strip surfaces. This allows much higher tensile forces to be
achieved and strips can be held tightly and controlled much
more accurately.
Even when applied to braking or tension rolls, these material

properties speak in favour of the non-woven roll. Because of
the strong and stable adhesion between the roll and the strip
surface, strips can be evenly pulled or control-braked, even at
Squeezing rolls
high plant speeds.
Squeezing rolls ensure lower residual moisture than rubber

or polyurethane coatings. On account of the capillary or suc-
tion effect of the non-woven material, fluid displacement at
the edges is reduced and the strip edges dry better. In addi-
tion, the special properties of non-woven materials prove
their worth in terms of resistance to cuts and durability.
Deflector rolls
As oiling or applicator rollers, non-woven coatings ensure the
uniform application and distribution of liquid coatings
because of their sponge effect. Due to their porosity and pore
volume, they are in the position to absorb liquid and under
pressure, to dispense it again evenly and/or to distribute it on
the surface.
Transport rolls /
Carrying rolls
The special surface protection which is created by absorbing
small dirt particles into the roller surface is apparent in pres-
sure rollers made of non-woven material, especially for soft
and sensitive surfaces, such as aluminium e.g. coil strips in
Tension rolls / cold rolling processes. Line speeds of over 1000m / min rep-
Brake rolls
resent no problem.
A similar situation applies to the use of non-woven roller as a

transporting or carrying roll. The soft and absorbent surface
of the roll prevents scratches or damage, thus ensuring the
smooth transfer of the strip.
Applicator rolls
34
Innovative equipment technology

5.1 Vacuum squeezing systems
By connecting of a pair of squeezing rolls made from special nology, which has been proven and established in Japan for
micro fibre non-woven material with simple vacuum technol- decades, it is sometimes possible to dispense entirely with a
ogy, we are able to offer an innovative, energy-saving and fan or hot-air dryer. As a result, a single line can achieve annu-
with it, a particularly environmentally-friendly system for al energy savings of up to EUR 100.000.
strip drying in a variety of process lines. Through this tech-
Product group OSBORN Product range
Complete systems including vacuum pump
Microfibre squeezing rolls
Complete units including frame construction

Vacuum squeezing rolls
Service and repair of used rolls
Supply of equipment for retrimming of used rolls
Bearing control and exchange
Dry surfaces and very low energy consumption - without hot air
The function of the system is simple. The role vacuum gener- Significant quality or process-related optimisation has also been
ated on the perimeter sucks the liquid remaining on the strip created through the vacuum technology, with absolute dry strip
surface into the roll, supported by the capillary action of the edges being just one leading example. Media displacement
micro fibre non-woven covering. Through the hollow shaft on through the gap in the squeezing rollers in the edge area is elim-
its perimeter, which has numerous holes on it, send is then fed inated entirely by the strong vacuum function and the need for
again, via the vacuum pump, to the existing fluid circuit. subsequent expensive/laborious drying is dispensed with.
35
Microfibre squeezing rolls in combination

with energy saving vacuum technology
The advantages of the vacuum roller especially come into

their own in comparison to conventional squeezing rollers on
shatter plates or extremely rough strip surfaces.
The rolls function with a very soft surface and only minimal
contact pressure. As such, the coating is significantly less
prone to wear and essentially more resistant to damage from
strip edges than is the case with traditional squeezing rolls.
Without its own power, the limited in-feed of the roll pre-
serves the condition of the rolls, as well as the bearing and
the line itself. This creates a lifespan for the rolls averaging
four to five years (depending on individual application) with
only minimal maintenance. All that is needed is one trimming
session and follow-up grinding of the roll surface from time
to time.
In the example below, of a typical strip cleaning line through

the use of NOVOTEX® non-woven rolls in the third and fourth
exchange of the squeezing roller pair, it would possible to dis-
pense with the hot-air drying facility entirely in favour of a
vacuum squeezing system.
Vacuum squeezing system

can replace hot air drying
Squeezing rolls
NOVOTEX®
Another important advantage is that this system innovation is

extremely simple to implement into existing strip lines. Only
the last pair of squeezing rolls in the plant has to be swapped
over. At the same time, the external dimensions of the rolls
normally remain unchanged and the existing bearings can be Water rinsing section
used. Even when additionally installed into an existing strip
line, the space requirement for a complete unit with a frame
construction is less than one metre in width. The vacuum unit Tell us your specific problem in detail and we will prepare a
itself also requires very little space and does not have to be proposal for a coherent optimisation concept.
placed directly on the pair of rolls.
36
Innovative equipment technology

5.2 Brushing equipment for strip processing lines
By linking our technological leadership in brush rollers with plant. Our focus primarily lies in swapping old machines
the competence and experience gained from teaming up with which no longer work optimally in existing lines, while at the
a whole range of line installers across the world we are, in same time optimising brush rollers and usage parameters in
cooperation with selected partners in the field of mechanical order to achieve sustainable quality and process improve-
engineering, in the position to offer well-engineered and indi- ments.
vidually adapted brushing machines and line concepts which
go further than the established standards of simple new
New intelligent concepts for brushing machines
Along with this background, we are also able to offer a new, fully • Easy and precise positioning of the rollers through mechanical
patented machine package which includes a variety of innovative clamping
developments:
• As a result: optimum and consistent, reliable feeding of the brush
• A rigid machine housing which is heavily cushioned against rollers via the immersion depth by means of height adjustment
vibrations and protected against corrosion, made of a composite using precision lifting spindle elements with a servo positioning
stainless steel/mineral cast construction motor (parallelism tolerance approx. 0.1 mm)
• Compact and extremely dense OSBORN HDL® brush rollers enable • Replacement of the rollers without disassembling the bearing units
precise control of the depth of immersion
• Optical control at any time through side access doors with large win-
• Easier and quicker replacement of the rollers within a few minutes dows on the operator side and the interior lighting of the plant
using an insertion skid with no additional dismantling tools
• Non-contact measurement of the roller diameter in operation
• Compact design enabling the unit to require little space - only
1500 mm for each upper/lower brush for strip widths up of to approx. • Optional construction according to the brush/brush principle
2000 mm
Brush / Brush Brush / Back-up-roll
Low vibration Increased vibration
37
For many years, lines according to the Japanese design have • In all, the performance of the respective strip cleaning unit
enjoyed a technologically leading role. In recent years, we is significantly improved, and in turn this can contribute to
have able to successfully realise new line projects with improving the strip quality and an increase in the line
renowned steel producers in Europe, North America, Asia and speed.
Africa together with our Japanese partners, by adjusting the
components to international standards. • Acquisition and maintenance costs are correspondingly
reduced.
• With these lines, the brush/brush principle instead of the
conventional brush/back-up roll design brings a number of • Above all, when exchanging brush machines in existing strip
advantages with it. lines, valuable space for additional pre-cleaning sections
can be achieved alongside more intensive brushes.
• Due to the halving the amount of roll pairs which are
required, a 50% space saving is achieved. • The contact surfaces strip/upper brush and strip/lower brush
are identical. This reduces vibrations. Through gentler run-
• In the case of thin straps, the brush in the border area no ning of the strip brush shading and shatter marks on the
longer works on the back-up roll but combs in the opposite strip surface are avoided.
brush. Fully uniform wear of the brush balling is achieved in
the border area through the additional oscillation of the
rolls.
Brushing machine in brush / brush construction including oscillation
38
Load Runners ®
6 Idler rollers and load rails
The name Load Runners® stands for five decades of experience Apart from an extensive standard program of over 300 arti-
in manufacturing of idler rolls and guidance systems for preci- cles in stock or available at short notice up to a diameter of
sion moving heavy loads in difficult conditions. Line builders 250mm, special sized rolls can also be tailor-made in small
and operators of rolling mills, strip lines or heat treatment quantities for special requirements.
plants trust in OSBORN’s coil, plate, tray and roller transport or
bearing equipment as well as the company’s automatic doors
and a whole host of applications based on this technology.
Load Runners® carry heavy loads in harsh environments
39
Load Runners® idler rolls are tightly sealed and greased for
Types
their entire service live. As such they are insensitive to dirt,
Plain Stud Style moisture and extreme temperatures. Long-life maintenance-
· radial and thrust loads free operation ensures high levels of economy without main-
· easy to install tenance.
Plain Eccentric Stud Style

The treads are made of high-strength steel and are then sur-
· radial and thrust loads face hardened to 55-60 HRC. As such they feature an espe-
· easy to install
· vertical adjustment cially wear-resistant surface with a tough core.
Plain Yoke Style The precision tapered roll bearings and grooved ball bearings
· radial and thrust loads used are particularly suitable for both radial and axial loads
· higher capacity than stud style
and can even be used at high speeds. This ensures key advan-
Flanged Stud Style tages over conventional needle bearings.
· radial and thrust loads
· easy to install Precision adjusted and hardened guiding rails made of high-
duty alloy steel are extremely resilient, wear resistant and
Flanged Eccentric Stud Style
free from twist effects. As such, heavy loads can be moved
precisely and reliably.
· easy to install
· vertical adjustment
Flanged Yoke Style

V-Grooved Stud Style

· roller profile sheds solid contaminants
V-Grooved Eccentric Stud Style

· vertical adjustment
V-Grooved Yoke Style

Cam Runner
· composite outer
· stainless steel shaft
· wet environments
U-Grooved Stud Style

· wire guides
· idler pulleys
· easy to install
Flanged Crown Style
· concentric and eccentric Our complete Load Runners range
· radial and thrust loads can be found in our catalogue,
· use on channels and I-beams “Load Runners® - Idler-Rollers and
Crown Yoke Style Load Rails for high-capacity load
· radial and thrust loads handling”.
Shafts for Yoke Style Idler-Rollers
40
Fill materials
7
Synthetic monofilaments - NON ABRASIVE
Novofil NM
Novofil NN
Novofil NH
Novofil HR
Novofil PR
Novofil PT
Novofil TR
Material group PA 6 PA 6.6 PA 6.12 PA Special PP PBT
Density (g/cm3) 1,14 1,1 1,07 1,14 1,16 0,9 1,5
Temperature resistance
Permanent (°C) 90 90 90 95 190 70 100
Max. short-term (°C) 120 120 120 120 250 100 130
Water absorption
(at 23°C) 10% 8% 3% 9% 7,50% <1% <0,5%
Mechanical properties
Bend recovery + + + + + 0 -
Stiffness - 0 + - 0 + +
Resistance to abrsion + + + + 0 0 -
Chemical resistance
Against alkalines + + + + + 0 0
Against acids - - 0 - + + +
Synthetic monofilaments - ABRASIVE

Novofil NN-A
Novofil NH-A
Novofil NN-S
Novofil NA-A
Novofil NH-S
Novofil NH-C
Novofil NA-S
Novofil HR-A
Novofil HR-S
Novofil NL-A
Novofil NL-S
Material PA 6.12 PA 6.12 PA 6 PA 6 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12 PA 6.12
Abrasive Material SiC Al2O3 SiC Al2O3 SiC Al2O3 SiC Al2O3 Al2O3 SiC Al2O3
Grit size 46-1000 80-1000 46-500 60-500 46-500 80-500 46-320 120-320 80-320 46-500 46-500
Density (g/cm3) 1,3 1,5 1,3 1,5 1,3 1,5 1,3 1,5 1,65
Permanent (°C) 90 90 90 90 95 95 90 90 90 80 80
Max. short-term (°C) 120 120 120 120 130 130 120 120 120 110 110
Water absorption
(at 23°C) 3% 3% 10% 10% 3% 3% 3% 3% 3% 1,50% 1,50%
Mechanical properties
Bend recovery + + 0 0 + + + + + 0 0
Stiffness + + 0 0 + + + + + 0 0
Resistance to abrasion + + 0 0 + + + + + + +
Chemical resistance
Against alkalines + + + + + + + + + 0 0
Against acids 0 0 - - - - - - - + +
41
Metallic and non ferrous wires
hoch temperatur-
hoch korrosions-
Phosphor-Bronze
Edelstahldraht
Edelstahldraht
Bessemer Wire
CD Steelwire
AB Steelwire
Brass coated
beständiger
beständiger
Brasswire
Steelwire
Steelwire
Steelwire
Cordwire
Stainless
Draht
Material group Carbon Steel Steel Steel Steel 1.4301 1.4401 Special Brass Steel Phosphor
steel legiert hochlegiert brass coated brass coated 1.4541 1.4571 soft Bronze
Type crimped crimped crimped crimpedcrimped crimped crimped crimped crimped crimpedcrimped
Density (g/cm3) 7,85 7,85 7,85 7,85 7,85 7,90 8,00 8,00 8,30 7,80 8,90
Permanent (°C) 300 300 300 300 300 620 500 1150 170 250 170
Wear properties
Elasticity modul (kN/mm2) 210 210 210 210 210 195 195 195 80 200 110
Zugfestigkeit (N/mm2) 1900 2100 2400 2300 1900 1800 1800 1600 900 700-1200 1000-1300
Hardness (Knopp) 480 500 630 530 530 370 400 160 200 330
Fatique resistance - 0 + + + 0 - + - - 0
Erosion performance - 0 + + + 0 - 0 - - -
Chemical resistance
Against alkalines - - - 0 0 + + + + - +
Against acids - - - - - 0 + + - - 0
Application nedium mittelschwer heavy medium heavy medium medium medium light light mittelleicht
Micro-fibre multifilament Natural fibres and animal hair

Novofil MY-A
Novofil MY-S
Novofil MX
Novofil MY
Horse hair
Tampico
Material group not abrasive abrasive Filament Material group Animal hair Natural fibre
abrasive mixture
Abrasive material - Al2O3 SiC SiC/Al2O3 Properties - very soft bristle - very good tem-
with low static perature resi-
Properties Micro-fibre multifilaments ae usu- charging and stance as well as
ally manufactured with high den- excellent sealing electric conducti-
sities into special OSBORN HDL® effect vity
brush constructions. - suitable for care- - used for dedu-
ful cleaning of sting, light clea-
The filament selection and specifi- extremely sensi- ning and to apply
cation will be defined and custo- tive surfaces, to polishing emul-
mized to the specific application. apply liquids or sions
for brush sea-
Our application engineers are glad lings
to be further assistance.
All information without engagement
42
Technical information
8
An optimal brush result is determined by different parame- surface speed, brush speed as well as depth of immersion
ters. After selecting the appropriate bristle as well as the and contact pressure have to be taken into account, and
brush design to be used, determining the fill density and individually defined under the given framework.
trim length in the process, the focus then turns to the cor-
rect operational parameters. In addition, criteria such as
Kissmark in dependence on depth of immersion and brush diameter Ø

120,00
100,00
80,00
Kissmark (mm)
60,00
40,00
20,00
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
Depth of immersion (mm)
Ø 250 Ø 300 Ø 330 Ø 350 Ø 400
Recommended surface speed / Rpm for different applications

2500
2000
Rpm (min-1)
1500
1000
500
0,00
150 200 250 300 350 400
Brush diameter Ø (mm)
Dedusting (10 m/sec) Cleaning (13 M/sec) Work roll cleaning (15 m/sec) Descaling (18 m/sec)
Different applications and fill materials require wholly dif- The tables in this section should provide approximate val-
ferent speeds. In turn, the appropriate speed depends on ues and indications. For detailed information and individual
the roll diameter. recommendations, please consult our application engi-
On the other hand, the optimum contact pressure can vary neers who will be happy to help.
greatly according to the brush construction and the fill den-
sity. The decisive factor in achieving the required brush
result is the immersion depth, as a brush tool works prima-
rily with the bristles and/or the tips of the wire.
43
Brush diameter (d) x π x speed (n)

Table of surface speeds in metres per sec. Surface speed (v) =
1000 x 60
Brush-Ø Surface speed (m/sec.)
(mm)
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
400 477 525 573 621 668 716 764 812 859 907 955 1003 1050 1098 1146 1194
390 490 539 588 637 686 735 784 833 881 930 979 1082 1077 1126 1175 1224
380 503 553 603 653 704 754 804 854 905 955 1005 1055 1106 1156 1206 1256
370 516 568 619 671 723 744 826 878 929 981 1032 1084 1136 1187 1239 1290
360 531 584 637 690 743 796 849 902 955 1008 1061 1114 1167 1220 1273 1326
350 546 600 655 709 764 819 873 928 982 1037 1091 1146 1200 1255 1310 1364
340 562 618 674 730 786 843 899 955 1011 1067 1123 1180 1236 1292 1348 1404
330 579 637 694 752 810 868 926 984 1042 1100 1157 1215 1273 1331 1389 1447
320 597 657 716 776 836 895 955 1015 1074 1134 1194 1253 1313 1373 1432 1492
310 616 678 739 801 863 924 986 1047 1109 1171 1232 1294 1355 1417 1479 1540
300 637 700 764 828 891 955 1019 1082 1146 4210 1273 1337 1401 1464 1528 1592
290 659 724 790 856 922 988 1054 1120 1185 1251 1317 1383 1449 1515 1581 1646
280 682 750 819 887 955 1023 1091 1160 1228 1296 1364 1432 1501 1569 1637 1705
270 707 778 849 920 990 1061 1132 1203 1273 1344 1415 1485 1556 1627 1698 1768
260 735 808 881 955 1028 1102 1175 1249 1322 1396 1469 1543 1616 1689 1763 1836
250 764 840 917 993 1070 1146 1222 1299 1375 1451 1528 1604 1681 1757 1833 1910
240 796 875 955 1035 1114 1194 1273 1353 1432 1512 1592 1671 1751 1830 1910 1989
230 830 913 996 1079 1163 1246 1329 1412 1495 1578 1661 1744 1827 1910 1993 2076
220 868 955 1042 1129 1215 1302 1389 1476 1563 1649 1736 1823 1910 1997 2083 2170
210 909 1000 1091 1182 1273 1394 1455 1546 1637 1728 1819 1910 2001 2092 2183 2274
200 955 1050 1146 1241 1337 1432 1528 1623 1719 1814 1910 2005 2101 2196 2292 2387
190 1005 1106 1206 1307 1407 1508 1608 1709 1809 1910 2010 2111 2211 2312 2412 2513
180 1061 1167 1273 1379 1485 1592 1698 1804 1910 2016 2122 2228 2334 2440 2546 2653
170 1123 1236 1348 1460 1573 1685 1798 1910 2022 2135 2247 2359 2472 2584 2696 2809
160 1194 1313 1432 1552 1671 1790 1910 2029 2149 2268 2387 2507 2626 2745 2865 2984
150 1273 1401 1528 1655 1783 1910 2037 2165 2292 2419 2546 2674 2801 2928 3056 3183
Significantly better brush performance is achieved through

the use of compact brushes and high quality fill materials.
Consequently, cooling plays a crucial role, as overheating
can quickly lead to the bristles becoming brittle causing
premature breakage to occur. The brush cooling facility in
the present plant/line is greatly optimised by correcting and
optimising the angle of spray and flow rate. In turn, this sig-
nificantly extends the service life of the rollers. Even the
selection of the correct spray jets plays an important role.
Terminology
APL: Annealing Pickling Line FL: Finishing Line

BAL: Bright Annealing Line GL: Grinding Line
BL: Brushing Line HAPL: Hot Strip - Annealing Pickling Line
CAL: Continuous Annealing Line HCM: Hot Continuous Mill
CAPL: Cold Strip - Annealing Pickling Line HHT: Horizontal Heat Treatment Plant
CCL: Color Coating Line HRC: Hot Rolled Coils
CGL: Continuous Hot-dip Galvanizing Line HFM: Hot Finishing Mill
CL: Cleaning Line HRFM: Hot Reversing Finishing Mill
CPL: Continuous Pickling Line HRM: Hot Reserving Mill
CRM: Cold Rolling Mill PL: Polishing Line
DL: Degreasing Line PLTCM: Pickling Section of Combined Tandem Cold Mill
DPL: Descaling Pickling Line SL/CCL: Slitting/Cross Cutting Line
ECL: Electrolytic Cleaning Line SPM: Skin Pass Mill
EGL: Electrolytic Galvanizing Line TLL: Tension Level Line
ETL: ElectrolyticTinning Line TM: Temper Mill (Kaltwalzgerüst)
44
Our further product range

9
OSBORN Load Runners®

Load handling systems for precise movement of heavy loads in demanding
industrial applications.
www.loadrunners.de
OSBORN TOP
High performance power brushes - Superior range for demanding applica-
tions and intense production conditions in industry.
www.top-brush.com
OSBORN Novofil®
Abrasive nylon brushes in Hi Tec filaments, rectangular and round in
Diamond, Zirconium, Aluminium Oxide and Silicon Carbide. Available in a
wide range of grit values.
OSBORN MultiStrip®
Saving thermal energy, reducing the passage of sound, protecting against
insect and vermin infestation, sealing against dust, dirt, water and smoke,
cleaning of industrial and commercial conveying systems.
www.multistrip.de
Microabrasive brushes and miniatur brushes

Flexible, highly efficient brushing tools for surface finishing of small bores
and cross hole deburring.
www.microabrasive-brush.com
45
Multizack system and punched roller brushes

Products for a wide range of applications: Brushes for cleaning, deburring,
transporting, sorting, washing, guiding and structuring.
Brushes for weld cleaning

Power driven brushes for the pipeline industry, e.g. cleaning the internal dia-
meters of pipe, external cleaning, edge prparation, removal of insulation
coatings, remedial work, cleaning weld seams prior to welding and weld
bead deslag.
www.pipelinebrush.com
OSBORN ATB®
ATB - Advanced Technology Brush System!
Disc brushes with abrasive high-tech filaments. ATB disc brushes have fill
density which is 4 times higher than other disc brushes manufactured accor-
ding to the conventional method (punched).
OSBORN Novoflex-B®
The flexible honing tool!
Lippert-Unipol, Polishing and surface finishing tools

The Lippert-Unipol product range contains the following products for any
kind of polishing and surface finishing applications:
Abrasive non-woven tools, abrasive brushes in various constructions, coa-
ted abrasive tools, polishing emulsions as well as polishing buffs and mops,
made from cloth, Sisal, Sisal/Cord, Sisal cloth and Notiflex non-woven
materials.
www.lippert-unipol.de
46
Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
03/09
2033 GB
Subject to alterations.
OSBORN International GmbH · Manufacturer of Industrial Brushes, Surface Finishing Tools and Load Runners
Ringstraße 10 · 35099 Burgwald-Germany · Phone: +49 (0) 64 51 / 5 88-0 · Fax: +49 (0) 64 51 / 5 88-208
eMail: techsales@osborn.de · www.osborn.de · www.metallurgy-brush.com
ISO 9001-2000 Certified Quality System Members of Jason Finishing Group

Osborn Roller Catalogue

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umbruch_engl_deu:umbruch_deu 05.03.

2009 15:07 Uhr Seite 1

Innovative Solutions for

Equipment & Systems

Members of Jason Finishing Group

2 Brush roll applications

2.1 Degreasing, washing and cleaning Page 5

2.2 Activation of strip surface Page 7

2.3 Roll cleaning and polishing Page 8

2.4 Strip polishing and finishing Page 9

2.5 Scale removal Page 11

2.6 Roll coating control Page 13

2.7 Transport roll systems for HHT furnaces Page 15

2.8 Transport roll systems for high temp applications Page 17

2.9 Transport roll systems for noise reduction Page 18

3 Brush roll systems

3.1 Complete brush roll systems Page 19

3.3 Customer Assembly (CA) brush roll systems Page 23

3.4 OSBORN HDL® brush rolls Page 25

3.5 Lipprite® abrasive non woven rolls Page 27

4 NOVOTEX® non-woven rolls Page 29

5 Innovative equipment technology

5.1 Vacuum squeezing systems Page 35

5.2 Brushing equipment for strip processing lines Page 37

6 Load Runners® idler rollers and load rails Page 39

7 Fill materials Page 41

8 Technical data Page 43

9 Our further product range Page 45

Specialised technology centres in our factories in Germany,

Brush roll service centers

Europe OSBORN International GmbH America OSBORN International Ltda.

OSBORN Unipol Ltd. OSBORN International

OSBORN International AB Asia Pacific OSBORN International China

Further contact details worldwide: www.metallurgy-brush.com

Brush roll applications

Carbon steel CGL, CAL, CL/ DL, ETL

OSBORN HDL ® - a new benchmark in strip cleaning

Besides brush rollers for degreasing and cleaning applica-

• LOAD RUNNERS® ensure a durable and maintenance-free

• Temperature and alkaline resistant brush sealing provides

• Vacuum squeezing systems set new standards in the com-

• In the modernisation of strip lines it is possible, through the

• NOVOTEX® squeezing rollers complete the OSBORN strip

OSBORN innovations for cleaning sections in strip processing lines

Alkaline brush Squeezing Brush cleaning Squeezing Squeezing

OSBORN HDL® NOVOTEX® OSBORN HDL® NOVOTEX® NOVOTEX®

Load Runners® Brush sealings

Alkaline spray Electrolytic Water rinsing Hot air dryer

Brush roll applications

Strip surface activation

OSBORN HDL ® - micro cleaning plus surface activation

Brush roll applications

Carbon steel SPM,TM, CGL Helimaster® Brush rolls, abr-

The brush roller itself is only part of

For the cleaning of deflector, shape control or thickness meas-

Brush roll applications

Today, increasingly higher demands are made on the final

Different types of rollers and coatings can also be used

A combination of Bessemer wire roller brushes and polishing

All-in-one solution made by OSBORN-UNIPOL

Polishing station with

UNIPOL® polishing emulsion

Lipprite® abrasive non woven rolls - for a perfect surface finish