High-Precision Corona Roll and Corona Nip Roll Shipped for Film Corona Treatment Line

Successful Shipment of Customized Corona Roll and Corona Nip Roll
We recently completed the manufacturing and shipment of a customized Corona Roll and Corona Nip Roll for a high-speed film corona treatment application.

The project includes a large-width Ø708 × 9,200 mm Corona Roll and a 570 × 9,200 mm Corona Nip Roll, both engineered according to demanding requirements for roller structure, rubber performance, dimensional accuracy and dynamic balancing.

In a modern film production line, the corona treatment section is an important process for modifying the surface properties of polymer films before printing, coating, laminating, adhesive bonding or metallizing. The Corona Roll and Corona Nip Roll are critical rollers in the traction and corona treatment section, helping maintain stable film transport and controlled contact conditions during continuous high-speed operation.

For wide film lines, roller precision is particularly important. Roller runout, cylindricity, rubber hardness, surface roughness, structural rigidity and dynamic balance can all influence the mechanical stability of the film web as it passes through the corona treatment area.

1. The Role of Corona Roll in Film Corona Treatment
The Corona Roll is a precision roller used in film surface treatment and traction systems. It supports the film web while maintaining controlled film movement through the corona treatment zone.

Polymer films such as BOPP, BOPET, CPP, PE and other plastic films generally have relatively low surface energy in their untreated state. Corona treatment modifies the film surface to improve its suitability for subsequent processes such as:

Printing
Coating
Laminating
Adhesive bonding
Metallizing
Ink adhesion
The mechanical performance of the Corona Roll is therefore an important part of maintaining stable film handling during the treatment process.

For high-speed film production, the roller must maintain its designed geometry and dynamic stability throughout continuous operation.

2. Corona Nip Roll: A Key Roller in the Traction Section
The Corona Nip Roll, also known as a corona pressure roller or corona nip roller, works together with the Corona Roll to provide controlled film contact and web traction.

The nip roller’s rubber surface provides the required mechanical contact with the film web. Its rubber hardness, thickness, surface roughness and geometric accuracy must therefore be carefully controlled according to the application.

For this project, the Corona Nip Roll uses EPDM rubber with a specified hardness of 50 ± 2 Shore A and a rubber thickness of 12–15 mm.

The roller is designed with:

Q355B outer tube
Forged flange
Forged disc head
EPDM rubber covering
G2.5 dynamic balancing
The combination of structural rigidity and controlled rubber properties provides a precision traction component for the corona treatment section.

3. Ø708 × 9,200 mm Corona Roll
The main Corona Roll supplied for this project has an overall specification of:

Ø708 × 9,200 mm

The large-diameter, wide-face construction requires careful control of shell fabrication, journal assembly, machining accuracy, rubber covering and dynamic balancing.

Corona Roll Technical Specifications
Parameter
Specification
Product
Corona Roll
Dimensions
Ø708 × 9,200 mm
Construction
Double-shell construction
Cooling Connection
Water inlet and outlet at the same end
Inner Shell Material
Q345B
Outer Shell Material
Q345B
Journal Material
42CrMo
Journal Assembly
Interference assembly
Rubber Material
Silicone Rubber
Rubber Thickness
4 mm
Rubber Hardness
75–80 Shore A
Surface Roughness
Ra 1.6 μm
Runout
≤ 0.10 mm
Cylindricity
≤ 0.10 mm
Dynamic Balance
G2.5
Maximum Speed
630 m/min

4. Double-Shell Construction and Same-End Water Connections
One of the key engineering characteristics of this Corona Roll is its double-shell construction.

Both the inner and outer shells are manufactured from Q345B, while the journals are manufactured from 42CrMo.

The roller incorporates a cooling system in which the water inlet and water outlet are positioned at the same end of the roller.

This configuration is particularly useful when the machine layout requires the cooling connections to be concentrated on one side of the roller.

For a large-diameter roller with a face length of 9,200 mm, structural stability and dimensional control are essential. The shell and journal assembly must provide sufficient mechanical integrity for continuous high-speed rotation.

The journal is assembled with the outer shell using an interference assembly process, providing a robust connection between the roller body and journal.

5. High-Speed Dynamic Balancing: G2.5
The Corona Roll is designed for a maximum line speed of:

630 m/min

At high operating speeds, even relatively small rotor imbalance can contribute to vibration and dynamic loading.

For this reason, the finished roller is dynamically balanced to:

G2.5

Dynamic balancing is particularly important for wide and large-diameter film rollers because stable rotational behavior helps support:

Smooth film transportation
Reduced mechanical vibration
Stable bearing operation
Reduced vibration transfer to the film line
Reliable continuous operation
Dynamic balance is therefore an essential part of the manufacturing process rather than simply an optional finishing step.

6. Silicone Rubber Surface for Corona Roll
The Ø708 × 9,200 mm Corona Roll is equipped with a 4 mm silicone rubber layer.

The specified rubber properties are:

Hardness: 75–80 Shore A

Surface Roughness: Ra 1.6 μm

Silicone rubber is selected for its combination of elasticity, surface properties and suitability for demanding industrial roller applications.

The rubber thickness and hardness must be controlled consistently across the entire 9.2-meter roller width.

Surface roughness is also controlled to Ra 1.6 μm, providing a defined surface condition for the film handling application.

7. 570 × 9,200 mm Corona Nip Roll
The second roller supplied for this project is the Corona Nip Roll, with dimensions of:

570 × 9,200 mm

It adopts a single-shell structure using a Q355B outer tube.

The roller is equipped with a forged flange and disc head, providing a robust mechanical structure for continuous industrial operation.

The roller surface is covered with EPDM rubber.

Corona Nip Roll Technical Specifications
Parameter
Specification
Product
Corona Nip Roll
Dimensions
570 × 9,200 mm
Construction
Single-shell structure
Outer Tube
Q355B
Flange
Forged
Disc Head
Forged
Surface Material
EPDM Rubber
Rubber Thickness
12–15 mm
Rubber Hardness
50 ± 2 Shore A
Surface Roughness
Ra 1.6 μm
Runout
≤ 0.10 mm
Cylindricity
≤ 0.10 mm
Dynamic Balance
G2.5

8. EPDM Rubber Surface for Corona Nip Roll
The Corona Nip Roll uses an EPDM rubber surface with a thickness of 12–15 mm.

The rubber hardness is specified at:

50 ± 2 Shore A

This controlled hardness provides a defined elastic surface for the nip application.

For a 9,200 mm-wide Corona Nip Roll, rubber uniformity across the full roller face is important. Variations in rubber thickness or hardness can influence the mechanical characteristics of the nip and film traction system.

The finished surface is controlled to:

Ra 1.6 μm

while the roller body is manufactured to:

Runout ≤ 0.10 mm

and:

Cylindricity ≤ 0.10 mm

9. Why Corona Roll and Corona Nip Roll Quality Matters
The Corona Roll and Corona Nip Roll are important components in the traction and corona treatment section of a film production line.

Corona treatment itself is an electrical surface modification process, but its stability also depends on the mechanical condition of the rollers transporting the film through the treatment zone.

A precision roller system helps maintain a controlled film path and stable web movement.

Key factors include:
1. Roller Runout

Excessive runout can introduce periodic mechanical variation during roller rotation.

2. Cylindricity

Good cylindricity is important for maintaining consistent roller geometry across the full working width.

3. Rubber Hardness

The specified rubber hardness determines the mechanical response of the roller surface during film contact.

4. Surface Roughness

Controlled surface roughness helps maintain consistent surface characteristics and film handling behavior.

5. Dynamic Balance

G2.5 dynamic balancing is important for high-speed rotating rollers and helps control vibration generated during operation.

6. Structural Design

For a 9,200 mm-wide roller, shell construction, journal design and flange/disc-head construction must be engineered according to the operating requirements.

10. Precision Manufacturing and Quality Inspection
Large-width film processing rollers require comprehensive inspection throughout the manufacturing process.

For this Corona Roll and Corona Nip Roll project, key quality-control requirements include:

Dimensional Accuracy
The roller diameter, overall face length, journal dimensions and critical assembly dimensions are controlled according to the approved technical specifications.

Runout Control
Both rollers are manufactured to:

Runout ≤ 0.10 mm

Cylindricity Control
The roller body is controlled to:

Cylindricity ≤ 0.10 mm

Rubber Surface Inspection
The rubber-covered rollers are inspected for:

Rubber thickness
Rubber hardness
Surface roughness
Surface uniformity
Surface appearance
Dynamic Balancing
Both rollers are dynamically balanced to:

G2.5

This is particularly important for the Ø708 × 9,200 mm Corona Roll with a specified maximum speed of 630 m/min.

11. Successful Shipment of Customized Film Treatment Rollers
After completion of structural fabrication, shell and journal assembly, precision machining, rubber covering, surface finishing, dimensional inspection and dynamic balancing, the customized Corona Roll and Corona Nip Roll were successfully completed and prepared for shipment.

This project demonstrates our manufacturing capability for large-diameter, extra-wide precision rollers used in film processing and corona treatment equipment.

The two rollers were designed according to different functional requirements:

Corona Roll
Ø708 × 9,200 mm

Double-shell construction, Q345B inner and outer shells, 42CrMo journals, same-end water inlet and outlet, 4 mm silicone rubber, 75–80 Shore A hardness and G2.5 dynamic balancing.

Corona Nip Roll
570 × 9,200 mm

Single-shell Q355B construction, forged flange and disc head, 12–15 mm EPDM rubber, 50 ± 2 Shore A hardness and G2.5 dynamic balancing.

The successful shipment represents our ability to integrate mechanical design, precision machining, rubber engineering and dynamic balancing into customized roller manufacturing for film production equipment.

12. Conclusion
For modern BOPP, BOPET, CPP, PE and other plastic film production lines, corona treatment is an important process for improving film surface characteristics for downstream printing, coating, laminating, bonding and metallizing.

The Corona Roll and Corona Nip Roll are critical rollers in the traction and corona treatment section, where stable film transport and precise roller performance are required.

For wide and high-speed production lines, roller selection should consider the complete engineering system, including:

Roller diameter + working width + shell structure + cooling design + journal construction + rubber material + rubber hardness + surface roughness + runout + cylindricity + dynamic balancing

The successful shipment of the Ø708 × 9,200 mm Corona Roll and 570 × 9,200 mm Corona Nip Roll demonstrates our capability to manufacture customized precision rollers for demanding film processing applications.

If you are looking for a customized Corona Roll, Corona Nip Roll, Corona Treatment Roller or Film Traction Roller, we can develop the roller according to your film width, line speed, equipment structure, cooling requirements and rubber specifications.

Contact Us
Huatao Group-Jenny Liu

Email: sale05@huataogroup.com
Website:https://www.huataomulti-indusrolls.com/film-industry/
WhatsApp / WeChat: +86 177 4378 9775

For customized Corona Rolls, Corona Nip Rolls, film traction rollers and other precision industrial rollers, please contact our engineering team for technical consultation and quotation.

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