SKY ENGINEERING

Since its foundation in 1866 LEONHARD BREITENBACH GmbH has grown up to a modern, world-wide operating company with a wide range of products and services. It was the outstanding quality of its products and services that helped the company to gain a firm place in the market and the fine reputation it enjoys today among all its customers for all questions related to rolls.

The production program of LEONHARD BREITENBACH GmbH comprises:

• calender- and mixing rolls
• rolls for crushing products of any type
• coating- and metering rolls
• heating- and cooling rolls
• rolling mill rolls
• rolls for food- and feed industry
• special rolls as well as
• pistons

The special power of the company lies in offering ready-to-install products adapted to the special needs of the customer. The possible roll material offered besides cast iron grades from its own foundry are all ferrous products and non-ferrous metals up to carbon fibre reinforced plastics.

For special surface problems the company offers innovative solutions to his customers. This i.e. hard chrome plated and nickel plated layers, thermally sprayed coatings as well as rubber and plastic coatings belong to its standard delivery program. Of course any other type of coating can be done.

The high qualification of its staff and the use of most modern production and testing equipment enables LEONHARD BREITENBACH GmbH to supply products matching with the highest demands put on surface quality as well as cylindricity and to close tolerances.

Besides the various possibilities for manufacture of rolls, quite a number of services are offered to the customers. These are besides design, construction, optimisation and refurbishment of rolls, contract machining and advise in all questions related to rolls.

Products

Calender, Mixing and Smoothening Rolls

Calendering, pressing, mixing and smoothening for these manufacturing processes, precision rolls are used in order to guarantee that the final products have the optimum properties.

It is obvious that rolls used for these purposes must meet extremely high standards, since the quality demands for production, converting and treatment of materials in continuous runs can only be achieved using rolls of maximum precision with respect to geometry, runout and surface finish.

Throughout the world, machine and equipment manufacturers as well as end-users involved in the processing of paper, foils, plastics, rubber etc. are our customers. All sizes of rolls are supplied in any design which may be required.

Through close co-operation with our customers we are fully familiar with their requirements. By purposefully gearing our production range and services to suit our customers' needs, we are able to develop and provide products now, which will meet future demands.

Rolls produced by Breitenbach are manufactured to comply exactly with customers' specifications or they are designed and produced in close co-operation with the end-user. Mechanical and thermodynamic strains are taken into account.

One-hundred-percent inspection is of great importance to us. Each manufacturing step is fully documented, because complete quality assurance is a matter of course for us. Research and development are considered as means of constant improvement of materials, processes and service, and these processes are continuous.

Coating and Doctor Rolls

Coating, painting, impregnating of materials in continuous runs such as paper, cardboard, plastics and metal foils, textile fabrics and non-wovens, this is the range of application for our rolls. Whenever materials in continuous runs are processed, high-precision coating rolls are needed, in order to meet the high quality standards which are specified for all final products.

The slightest deviation in cylindricity and runout may lead to significant differences in the coating quality and thickness. The more precise the roll, the better coating quantity and uniformity specifications can be met. When calculating the savings for one production year or even for the service life of the rolls, the investment in roll precision will pay off.

At Leonhard Breitenbach GmbH, the standards for quality and precision are extremely high. This has made us the market leader for this product range on a worldwide basis.

Heat Transfer and Chill Rolls

Heating and cooling. The production of paper, foils, plastics, rubber etc. in continuous runs usually requires thermal treatment of the material during the production process.

Whether during manufacture, converting or processing, a correct roll temperature with least tolerance is vital.

In order to guarantee constant product quality and properties, the standards set for both heat transfer and chill rolls are extremely high.

With regard to planning and design, we place our trust in our in-house research department. Thermodynamic simulation and calculation is made, on the basis of which design engineers develop individual solutions. This enables us to design and to manufacture heat transfer and chill rolls which are characterised by an extremely uniform distribution of temperature on their surface.

Controls and checks accompany the complete production process and guarantee a consistently high quality level.

Idler and Guide Rolls

Idler and guide rolls are used wherever materials in continuous runs are manufactured, processed or converted. Even though this type of roll is often considered to be of secondary importance, idler and guide rolls must meet relatively high quality standards with respect to runout, surface finish and operation.

Breitenbach supplies idler and guide rolls for all applications. These rolls are manufactured with the same care and applying the same high-precision machining methods as for instance in the production of calender rolls. We are in a position to supply idler and guide rolls with a runout in the range of microns which meets all requirements im-posed by high-speed systems.

Crushing Rolls

Grinding, refining, squeezing, crushing, flaking these are tasks putting rolls into focus as the most important tool. Highly precise crushing rolls made by Leonhard BREITENBACH GmbH are, amongst other applications, used for preparing the following products:

• foodstuff including luxury foods
• animal feed
• pharmaceutical products
• colours
• fertilizers
• ceramics and stoneware

BREITENBACH crushing rolls enhance the efficiency and profitability of various production processes in several respects. On the one hand, maintenance intervals are significantly extended without affecting reliability. This means longer machine cycles without interruption, and the repair costs are cut down to the required minimum. Reduction in energy consumption during grinding is another important benefit offered by our rolls. Furthermore, we have continuously developed our products and adapted them to actual market requirements, in close cooperation with renowned mill and plant manufacturers.

This dialogue in partnership along with our experience over many years makes BREITENBACH a reliable partner specialising in the field of roll manufacture for all crushing applications.

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