Thermoplastic polyurethane (TPU) has revolutionized conveyor belt production, offering unparalleled advantages that make it the material of choice for many industries. BG Plast has excelled in the development of TPU-based conveyor belt extrusion lines, both coextruded and monolithic. Advanced technology and our commitment to quality have earned us a reputation among the top companies globally.
TPU conveyor belts produced by calendering enhance the advantages of the material
Versatility and durability of TPU
Thermoplastic polyurethane (TPU) bridges the gap between rubber and plastic to stand out as a highly versatile elastomer. This adaptability is due to its unique combination of properties, making it ideal for a variety of industrial applications. One of the key characteristics of TPU is its high flexibility, which remains constant even at extremely low temperatures that reach -30°C. This feature is particularly advantageous in environments where temperatures fluctuate widely or reach extreme lows, ensuring that conveyor belts maintain their performance without becoming brittle or losing elasticity.
In addition to its flexibility, TPU has excellent abrasion resistance. This means that TPU-coated conveyor belts can withstand continuous friction and wear without significant degradation, extending their service life compared to other materials. A crucial feature in industries such as mining, manufacturing and logistics, where conveyor belts are subjected to constant movement and heavy loads.
Chemical resistance is another essential attribute of TPU. Conveyor belts often come into contact with various chemicals, oils and solvents. The material’s resistance to these substances prevents the belts from deteriorating, cracking or weakening, thus maintaining structural integrity and performance. This advantage makes TPU-coated tapes suitable for use in chemical plants, food processing units, and other environments where exposure to harsh chemicals is common.
In addition, the toughness of TPU provides conveyor belts with high wear and impact resistance. This toughness translates into lower maintenance requirements and lower replacement costs, as the belts can withstand harsh conditions without being damaged. Unlike other materials, TPU does not develop micro-fractures on its surfaces, which can lead to failure over time. On the contrary, it maintains a smooth and robust surface, ensuring the reliability and longevity of belts under harsh conditions.
The combination of these properties-flexibility, abrasion resistance, chemical resistance, and toughness-makes TPU a superior material for conveyor belt applications. Its ability to perform reliably in diverse and demanding settings highlights its versatility and underscores why TPU is the preferred choice for high-quality, durable conveyor belts.
The extrusion calendering process of TPU conveyor belts
The extrusion calendering process is central to manufacturing high-quality TPU conveyor belts. This method begins by feeding TPU granules into an extruder. After initial drying to compulsorily remove residual moisture, the granules are processed in a single-screw extruder at low/medium screw RPM. This step is crucial because it determines the basic characteristics of the TPU film, ensuring its uniformity and consistency.
Once extruded, the TPU film undergoes calendering, a critical step in which it is passed through a series of rollers to achieve the desired thickness. This calendering process not only refines the film but also improves its mechanical properties.
Through calendering and multilayer composite embossing, the final conveyor belt is produced. Each layer of this multi-step process is carefully and thoroughly applied to ensure that the tape maintains a perfectly smooth, homogeneous and non-porous surface. The embossing phase adds texture or pattern to the surface of the belt, enhancing its grip and functionality for specific applications.
The extrusion-calendering process not only improves belt life, but also ensures consistent product quality. By maintaining strict control over every step of the process, from initial extrusion to final embossing, conveyor belts can be produced that meet the highest standards of performance and reliability. The efficiency of this method allows high production rates to be achieved while maintaining the integrity and superior characteristics of the TPU material.
The calendering extrusion process enables excellent precision of the final product
Advantages of the calendering process for TPU belts
The calendering process offers several significant advantages that make it a superior choice for the production of high-quality TPU conveyor belts.
Preservation of molecular structure
One of the main advantages of the calendering process is the ability to maintain the molecular structure of raw TPU materials. During the calendering process, the material is heated and passed through rollers that shape and refine it without altering its fundamental molecular properties. This preservation ensures that the physical properties of the finished product, such as elasticity, strength and durability, remain intact. By avoiding structural changes that can occur during the coating process, calendering ensures that TPU conveyor belts maintain their optimal performance characteristics.
Uniform thickness
Calendering excels in producing a layer with uniform thickness for conveyor belts. The precision of the roller system used in calendering allows the thickness of the TPU layer to be accurately controlled. This uniformity is critical for the consistent performance of conveyor belts, as variations in thickness can lead to weak spots that are prone to wear and failure. Uniform thickness ensures that belts can withstand the stresses of industrial use without compromising their structural integrity.
Compact molecular structure
The calendering process results in a more compact molecular structure of the TPU material. During calendering, the molecules align and compact, increasing the density and overall strength of the material. This compactness significantly improves the conveyor belt’s resistance to wear, abrasion and winding. A denser molecular structure means that belts are less likely to develop micro-cracks or surface imperfections that could lead to premature failure. Increased wear resistance ensures the durability of conveyor belts, reducing maintenance costs and downtime.
Energy efficiency
Another key advantage of the calendering process is its energy efficiency. Unlike the coating process, which requires conversion of TPU from granular to powder and subsequent application in a multi-step process, calendering works directly with TPU granules. This direct approach eliminates the need for additional, energy-intensive steps of pulverizing and reprocessing the material at low temperatures. By simplifying the production process, calendering not only saves energy but also reduces overall processing costs. This efficiency makes the calendering process more environmentally friendly and cost-effective, contributing to sustainable production practices.
Improved product quality
In addition to the specific benefits described, the calendering process contributes to the overall improvement of product quality. The precision and control inherent in the calendering process ensure that each conveyor belt produced meets the most stringent quality standards. The resulting belts are more reliable and durable, able to perform even under the harshest conditions. High quality results in better performance in various applications, from the harshest industrial environments to specialized fields that require accurate material handling.
BG Plast can provide machinery tailored to each customer’s needs
BG Plast’s technological advantage
BG Plast’s success in TPU-based conveyor belt lines depends on our state-of-the-art technology and dedication to quality. The extruder-head-calender combination is critical to achieving high-quality products. By optimizing this configuration, we ensure that conveyor belts produced with our machinery meet the highest standards of performance and durability. This technological advantage, combined with our commitment to innovation, makes us a benchmark for the industry.
To get the maximum benefits of TPU conveyor belts, such as flexibility, abrasion and chemical resistance, rely on BG Plast. With advanced extrusion and calendering machinery, we enhance these features to produce superior quality belts compared to traditional coating processes. Ask for more information for your project.