Controlling Web Temperatures

7 Myths About Heat Transfer Rolls First published in Flexible

Packaging Magazine

Some are called chill rolls, some

are called heating rolls. In most cases,
these engineered rolls all serve a similar
purpose – to transfer heat energy onto or
away from a web.
Heat transfer rolls are common in
many converting processes today. As
engineered film and specialty substrates
become more prevalent, the use of these
engineered rolls has increased even more.
Yet, the physics of heat transfer rolls are Large or small ... single wall or
often misunderstood. This can result in double wall ... heat transfer rolls
incorrect roll specifications and improper have an important job to do. The
use that can directly affect web quality. more you know about how they
Though one doesn’t have to be an function, the better performance
engineer to properly specify and use heat you will achieve over the life of
transfer rolls, a little of the right know- the roll.
ledge can go a long way in maintaining the
ideal process parameters. The following but when not available, a computer model fluid like an auger. In a properly filled roll
seven heat transfer topics are common or heat transfer simulation must be used with the air bled off, the spiral channels have
misconceptions we routinely encounter. to model the application. The engineer no effect on the fluid inside as the roll turns.
Let’s clear up these issues now and you’ll can use this data to design the roller with Think of a double-wall heat transfer roll
be well on your way to becoming a heat the correct internal fluid path, optimizing as a pipe bent into a helical shape. Pumping
transfer myth buster. turbulence and maximizing heat transfer water from one direction or the other does
performance. not change
Myth #1 “All heat transfer rolls The goal is to achieve balance how the water
are pretty much the same.” through proper utilization of the flows through
It’s not right to say all car engines available flow rate, achieving turbulent the pipe. Turn
are pretty much the same. Different flow, while at the same time minimizing or rotate the
materials and engineering makes a sig- pressure drop. pipe, and the
The physical performance of the flow still remains unchanged – for practical
nificant difference in product life and
roller must also be considered. Roll purposes the water “doesn’t care” if the pipe
performance. The same is true for heat
body deflection and journal stress itself is moving, the water is moving only in
transfer rolls. With converters trying
are among the most important details relationship to the pipe itself. Consequently, it
to maximize performance of their
when engineering a roll for a specific does not matter which direction the roll turns.
equipment, most applications require
application. Particular design techniques Some customers still want “inlet,”
some serious engineering to optimize
and special materials can be used to “outlet” and “directional rotation” stamped
heat transfer.
reduce or manage challenges with design on the outside of their straight-pitch heat
Designing the right roll starts with
details, such as deflection and stress. transfer rolls and that is okay. In reality, it
the right operating data. Field data is best,
In some cases, an FEA (Finite Ele- really doesn’t matter which is which. Only
ment Analysis) is required to determine on a variable pitch or “gain-pitch” roll does
the best materials and structure for the fluid need to be introduced at a specific end
heat transfer roller. of the roll.

Myth #2 “Rotational direction must Myth #3 “Roller temperature can be

be matched with FLow direction.” controlled by the FLOW rate.”
FEA (Finite Element Analysis) is also used In a partially filled heat transfer roll, Heat transfer rolls are designed to
in heat transfer roll design to identify gravity pulls fluid to the bottom of the achieve a certain fluid velocity and turbulence
deflection forces. roll where spiral channels can push the in order to produce a transfer of energy,
all while maintaining a desired Delta T Myth #4 “The supplier will know Myth #5 “A double-wall heat
(symbolized as q T, this is the difference
in temperature of the fluid entering
what surface finish i need for my transfer roll is always the
vs. leaving the roll, or the temperature process.” correct choice.”
gradient across the roll face). It’s common for a customer to ask for Whenever the goal is to control web
When fluid flow is increased, the a “mirror finish” on their heat transfer roll temperature, a double-wall spiral heat
dynamics of heat exchange within the roll, … or a “matte” finish. In most cases, these transfer roll is imperative. Sometimes
along with q T, change. When energy is terms are used too loosely. the goal is simply to maintain a general
transferred into or away from a fluid, the Surface finishes are specified by Ra temperature of a specific roll. Then, a
flow rate of that fluid must be adequate – a value representing the roughness or single-wall heat transfer roll becomes the
to support the rate of heat transfer taking peak-to-valley measurement of a surface. most cost-effective solution.
place. If the flow rate is inadequate, the An Ra under 4 micro inches is typically
result will be a large q T. considered a mirror finish. Mirror finishes Examples: A rubber-covered nip
can go lower than .5 Ra, but cannot be roll opposing a heated roll – the
mechanically measured at that tolerance bond between the rubber covering
without damaging the surface. The lower and the roll core might be at risk if
the number, the finer the finish and more the nip roll gets too hot. A single-
exact the reflection. Accordingly, cost wall, rubber-covered heat transfer
goes up as Ra goes down. roll easily maintains an acceptable
Matte finishes are even more varied nip roll temperature. In a different
than mirror specifications, sometimes application, heated single-wall rolls
requiring both an Ra value and a gloss are used to keep an adhesive coating
rating. warm during a coating operation.
Specifying the proper Ra is critical
While fluid temperature should be in achieving the desired web finish. Clear Myth #6 “Any water will work in a
adjusted to control roll temperature, the web finishes require roll finishes at the heat transfer roll.”
higher the difference between web and lower Ra range. Not every converter Water chemistry varies throughout
roll temperature, the higher the heat needs a perfectly clear web – nor the cost the country and it’s a known fact that
transfer driving force and the greater associated with a fine mirror finish roll water acidity, scale and hardness can
the fluid flow rate must be to maintain If the needed Ra spec is unknown, affect the life and performance of a heat
consistent temperature across the face of a good roll provider can often help by transfer roll.
the roll. either examining a sample of the finished Some customers run city water,
product, or the existing roll. Examining an ground water or even river water through
Example: Over time, the heat load was existing roll is preferred. their heat transfer rollers. Untreated water
increased on a 48" diameter hot oil roll Process knowledge and experience can contain all sorts of unwanted minerals
designed to bond two webs. The roll is key to determining the proper finish and a chemistry that causes excessive rust
was originally designed at a specific on a roller; but many times, assistance and other deposits to build up in the flow
flow rate that was no longer adequate to can be provided over the phone by an passages of a heat transfer roll.
support the process. To compensate for experienced roll provider who understands A closed-loop system that uses
the increased heat load, the operators coatings and finishes. Specific and conditioned and treated water is the ideal
increased the oil temperature; but the measurable values must be used to way to ensure the life and performance of
roll design restricted the fluid flow specify a roll surface finish. Avoid using a heat transfer roll. It’s not much different
rate. The result was oil temperature at ambiguous terms such as “mirror” or than the coolant system in your car.
380°F coming in and 340°F exiting (a “matte” that mean something different to Properly maintained with the correct fluid
40 degree q T). The web was getting everyone who encounters them. chemistry, the system will operate trouble
“burnt” on the entry side of the roll
and not bonding on the exit end. The free for years.
solution was in the design of new rolls
with larger journals that could accept a
much higher flow rate to get q T to less
Myth #7 “Bigger is
than 10°F. always better.”
It is true that heat
q T is controlled by flow – and that is transfer is all about dwell
almost exclusively determined by the time (web on roll). It is also
design of the roll. By design, q Ts can be true that a larger roll will
achieved as low as 1°F. The appropriate give you a longer contact
q T for any application is dictated by the surface and therefore more
criticality of the process. Fluid tempera- dwell time. Yet, there are
ture will control roll temperature but flow other factors in play.
rate is ultimately the driver to uniform q T.
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 A boundary layer is a component processes is the key to success. Like many to review the facts and get some expert
in the system inhibiting or slowing products, a heat transfer roll is engineered advice.
heat transfer. In this case, the principle for optimum performance based on
boundary layer is air trapped between specific operating parameters.
the web and the roll. This boundary layer It is important to remember that flow
is a function of web speed, web tension rate and q T are inverse proportions. With
and roll diameter. As the roll diameter all other things remaining the same, if a
increases, so does the boundary layer, q T of 10 needs to be 5, the flow rate has
diminishing heat transfer. to double. Going from 2°F to 1°F doesn’t
In addition, the use of smaller, sound like much, but it is still double.
multiple rollers can be configured to There are various roll designs
contact both sides of the web. This available to achieve any desired energy
can be a real advantage with thicker transfer rate, including gain pitch spiral
webs. Finally, the cost of two smaller designs with varying flow velocities
rollers may be less than the cost of one and temperature differentials. Look to
larger roller. a qualified roll producer with certified
engineering in-house to provide the
Conclusion: necessary roll design.
The transfer of energy is critical Web temperatures can be measured
to many processes in web converting. today using a relatively inexpensive hand-
Effective, predictable and efficient held pyrometer. When temperatures are
heat transfer is paramount to process not what they should be, don’t touch that
performance – and understanding these dial. Call a heat transfer roll specialist