Key Features
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Wear Resistance: Vickers hardness of 1,500–1,800 HV, extending service life by 5–10x compared to steel rollers.
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Thermal Stability: Operate continuously at 1,200°C (zirconia) or 1,600°C (alumina), ideal for high-temperature dyeing and heat-setting processes.
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Chemical Inertness: Resistant to acids, alkalis, and organic solvents, ensuring longevity in corrosive environments like chemical finishing.
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Lightweight Design: Density of 3.8–6.0 g/cm³, reducing rotational inertia and energy costs by 20–30%.
Ceramic Rollers-Precision & Durability Redefined
Ceramic rollers are engineered components designed for high-performance textile machinery, offering unmatched wear resistance, thermal stability, and corrosion immunity. Made from advanced ceramics like alumina (Al₂O₃) and zirconia (ZrO₂), these rollers excel in applications such as spinning, weaving, dyeing, and finishing, where traditional metal rollers fail due to abrasion or chemical exposure. Their lightweight design reduces energy consumption while maintaining dimensional stability under extreme conditions.
By Features
Ceramic rollers are mainly used in textile machinery and are also commonly used in other working environments that require rotation. The following are some of our representative products.
Assembled on textile machinery and equipment to guide yarn.
Wire guide utilizing the properties of silicon nitride.
Ceramic Roller Applications
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Spinning: Guide rollers for ring-spinning and rotor-spinning machines, minimizing fiber breakage and improving yarn evenness.
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Weaving: Tension control rollers in looms, reducing warp breakage and enhancing fabric quality.
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Dyeing & Finishing: Heat-resistant rollers for stenter frames, ensuring uniform fabric drying and coating.
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Nonwoven Production: Calendering rollers for meltblown or spunbond lines, providing precise pressure control.
Technical Specifications
| Property | Alumina Rollers | Zirconia Rollers |
|---|---|---|
| Hardness (HV) | 1,500–1,800 | 1,200–1,400 |
| Max. Temp. | 1,600°C | 1,200°C |
| Thermal Conductivity | 24 W/m·K | 2–3 W/m·K |
| Surface Finish | Ra ≤0.1 µm | Ra ≤0.2 µm |
Advantages Over Metal Rollers
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Reduced Maintenance: No lubrication required, with 90% fewer replacements in abrasive environments.
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Energy Efficiency: Lower friction coefficient (μ ≈ 0.1–0.3) cuts power consumption by 15–25%.
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Customization: Available in diameters from 10 mm to 500 mm, with grooved, flanged, or tapered designs.
Ceramic rollers outperform steel in abrasive and high-temperature environments due to their ultra-high hardness (1,500–1,800 HV) and thermal stability (up to 1,600°C). For example, alumina rollers in spinning machines reduce fiber breakage by 40% compared to steel, while zirconia rollers in stenter frames withstand continuous heat without deformation. Their non-porous surface also resists chemical corrosion, extending lifespan by 5–10x and reducing downtime.
Regular inspection for micro-cracks using ultrasonic testing is critical. Clean rollers with non-abrasive solvents (e.g., ethanol) to avoid surface damage. For high-speed applications, ensure alignment within ±0.01 mm to prevent uneven wear. Recoating with wear-resistant materials like chromium oxide every 2–3 years can further enhance durability.
Yes. Custom designs include grooved rollers for fiber alignment in carding machines and hollow rollers with internal cooling channels for heat-sensitive fabrics. Precision CNC machining achieves tolerances of ±0.005 mm, critical for high-speed weaving looms. Materials like silicon nitride (Si₃N₄) are also available for extreme wear resistance.
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Printing: Precision rollers for ink transfer with Ra ≤0.05 µm surfaces.
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Packaging: Corrosion-resistant calendering rollers for laminating films.
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Paper Manufacturing: High-pressure rollers for dewatering and smoothing.
A mirror-polished surface (Ra ≤0.1 µm) minimizes fiber friction, reducing yarn hairiness by 30% and improving tensile strength. For example, in ring-spinning machines, smooth ceramic rollers decrease energy consumption by 20% while maintaining consistent yarn diameter.