Matt Finish Calendering Roller

·Uniform roughness across the entire roller with stable adjustable Ra range of 0.2–3.2μm and roller surface roughness deviation ≤±0.05μm, eliminating inconsistent haze between film edges. Unlike the common problem of uneven sand texture depth on simple sandblasted rollers, Guangyu employs a CNC enclosed fully automatic sandblasting system with uniform roller rotation and multi-angle reciprocating spraying technology. The kinetic energy of abrasive particles is digitally controlled throughout the process, effectively ensuring uniform matte texture from end to end on 3600mm ultra-wide rollers. A single production line can stably output various textures including matte, semi-matte, and soft matte, solving the batch-to-batch haze fluctuation problem in high-end matte film and decorative sheet mass production.

·Gradient stress-relief substrate combined with spiral enclosed temperature-control channels achieves continuous working roller surface temperature differential ≤±0.7℃, preventing localized bright spots and light-dark streaks during high-speed calendering. The roller body uses quenched and tempered alloy steel integral forging, with multiple vibration stress relief processes eliminating welding and machining internal stress. Internally integrated milled double-layer spiral heat exchange channels ensure balanced thermal fluid circulation throughout the entire roller. Under long-term calendering conditions at 160–240℃, there is no matte surface melting due to localized overheating or localized high-gloss streaks, suitable for 200m/min high-speed continuous mass production of BOPP matte films and PET decorative films.

·Composite hard chrome layer with dense matte substrate resists filler wear and material accumulation, maintaining long-lasting matte surface texture with repair cycle extended by 90%. Ordinary sandblasted rollers only have sand surface treatment on the substrate surface, making the sand pits easily worn by calcium carbonate and talc fillers in films, causing texture failure within a short period. Guangyu's process first performs precision sandblasting to form the base sand texture, then deposits a low-microcrack hard chrome protective layer that tightly bonds with the sand surface. When processing PLA, PVC, and filled modified films, additive extracts do not easily accumulate, requiring only routine water cleaning, greatly reducing offline polishing and re-sandblasting frequency.

·Dynamic balancing grade G1.0 with radial runout ≤0.003mm at high speed prevents wrinkling and periodic pressure marks on wide-width thin materials during calendering. Industry standard matt rollers typically achieve only G2.5 dynamic balancing, prone to periodic vibration marks at high speed. Guangyu factory implements G1.0 high-precision dynamic balancing calibration with integrally forged journals at both ends. For calendering ultra-thin films and nonwovens with thickness of 12–100μm, it effectively avoids film fluttering, transverse wrinkling, and periodic light-dark transverse marks, reducing scrap rates in thin material production.

·Customizable sand texture types: uniform matte sand, fine soft matte sand, irregular matte sand, and micro-brushed satin textures, not limited to single-particle sandblasting effects. Breaking through the industry limitation of only providing standard round particle matte finishes, CNC sandblasting path programming enables replication of customer sample matte textures, achieving various surface structures including irregular soft matte, directional micro-brushed satin, and fine matte sand. The finished product combines matte appearance with excellent printing adhesion, suitable for customized requirements in high-end packaging, electronic protective films, and automotive interior films.

·Process Stability: The core mission of the matt/satin calendering roller is not to create three-dimensional patterns but to uniformly smooth substrates and impart stable matte texture. Many manufacturers simply modify embossing rollers with sandblasting to serve as matt calendering rollers, resulting in uneven stress distribution and large sand texture depth fluctuations. Guangyu matt calendering roller features specialized structural optimization: uniform roller wall thickness design to avoid temperature differences during heat treatment; pre-grinding of the roller body to uniform roundness before sandblasting, establishing sand texture on a high-precision reference circular surface; balanced calendering pressure distribution ensuring flat film compression, effectively eliminating fish eyes and wrinkles while stably forming a continuous uniform matte surface layer.

·Operational Cost-Effectiveness: The sand surface wear resistance cycle significantly exceeds conventional sandblasted rollers, with much longer intervals between re-sandblasting under identical conditions, reducing production line downtime. The dense chrome layer resists corrosion when processing acidic biodegradable films and PVC materials with high plasticizer content, preventing sand surface pitting. Localized minor wear supports localized sand repair without complete re-sandblasting, lowering maintenance costs. The roller surface resists film adhesion and low-molecular additive accumulation with reduced cleaning frequency, suitable for 24/7 continuous production lines.

·Product Quality Enhancement: Controllable film haze with consistent texture both transversely and longitudinally, ensuring stable adhesion in subsequent UV printing, hot stamping, and lamination processes. Full stress release on the substrate surface after calendering reduces the risk of curling and shrinkage deformation in finished products. No periodic vibration marks or localized bright spot defects, significantly improving yield rates for high-end matte packaging films and label films.

·Biaxially Oriented Film Industry: Suitable for BOPP matte packaging films, BOPET decorative films, CPP matte composite films, PLA biodegradable matte films calendering and matting. Produces low-reflection matte substrates widely used in premium gift packaging, daily chemical labels, and food flexible packaging, with extensive supply to film manufacturers in Southeast Asia and the Middle East.

·Cast Films and Functional Protective Films: CPE cast films, electronic release films, screen protective films matte treatment. Through precise control of matte texture, achieves anti-glare effect on films, enhancing the appearance grade of electronic products.

·Synthetic Leather and TPO Automotive Interior Skins: PU/PVC synthetic leather surface soft matte calendering to eliminate high-gloss reflection, creating delicate matte leather hand-feel. Suitable for automotive seat skins and instrument panel surface finishing processes.

·Nonwoven Finishing Calendering: Spunbond and spunlace nonwoven matte smoothing to improve fabric flatness while adjusting surface friction coefficient, used for home textile nonwovens, decorative nonwovens, and hygiene material surface matte treatment.

·PVC and ABS Decorative Panels: Indoor decorative sheets and furniture decorative panels surface calendering and matting, replacing lamination processes with uniform matte texture and improved anti-fingerprint performance.

·Paper and Premium Printing Lamination: Matte laminating unit supporting calendering rollers, achieving soft matte effect after paper lamination, enhancing the premium feel of printed graphics, suitable for art books, deluxe bound books, and premium greeting card production lines.