Modular high-tech calendering platform shaping the future of tyre R&D

In today’s rapidly evolving tyre industry, innovation is no longer optional, but it's essential. Manufacturers are pressured to deliver products with lower rolling resistance, improved grip, reduced noise, and superior efficiency, all while accelerating development cycles for new materials and construction technologies. To support this transformation, Comerio Ercole has engineered a breakthrough solution: Miniduplex, a mini and modular calendering line purpose-built for fabric and steel cord rubberizing processes, fully aligned with Industry 5.0 and IoT digital ecosystems.

Created as a compact but fully equipped R&D and pilot-production line, Miniduplex enables tire manufacturers to test new materials, compound formulations, and process technologies; run short production campaigns with reduced setup times; validate structures before industrialization; produce samples for market testing or sudden production needs. Its flexibility makes it ideal for R&D centers, pilot plants, and innovation hubs in the tire sector.

The dual Miniduplex line integrates both textile and steel cord unwinding systems, a high-precision calender, and a modular winding section. Key subsystems include textile feeding section – fabric let-off with automatic braking torque control; splicing press or sewing machine; modular heating unit; centering and spreading devices – and steel cord feeding section – pneumatic tension controllers; unwinding spools and support frames; steel-to-textile splice press; grooved pressure rolls for calender coupling.

At the core of Miniduplex lies the Comerio Ercole CG4 4-roll calender, in “S” configuration, featuring Hydrogap hydraulic roll displacement; cross-axis and roll-bending systems for precision control; on-roll thickness gauges ensuring micron-level accuracy; advanced temperature control units; integrated stock guides, edge trim knives, and bubble-piercing devices. This configuration ensures exceptional thickness uniformity, even with complex rubber compounds. A complete downstream process enables full-spec pilot production and includes thickness gauging with automatic feedback; multi-stage cooling drums; hydraulic festoon accumulator; center guiding; pulling, locking, and cross-cutting; dual shuttle winder with automatic tension control.

Miniduplex can begin as a laboratory platform and later be upgraded with industrial-grade feeding/extrusion units; high-capacity winding systems; process automation enhancements; extended width or speed capabilities. This adaptability allows the system to evolve with customer needs. One of the most disruptive developments is the containerized calendering line. The entire Miniduplex system can be installed across seven containers, each pre-assembled, pre-wired, and tested. Benefits of this solution are mobility across multiple production sites; plug-and-play installation; rapid start-up; full R&D and pilot-production capabilities anywhere. Container modules include steel cord creels (120–444 spools); fabric storage and let-off; heating, drying, and centering units; complete calender module; accumulator and winding module; utility container (TCS units, hydraulics, lubrication); electrical container (automation cabinets, air-conditioned); pre-warming container with pin extruder + open mill. This unique mobility expands R&D flexibility worldwide.

Technical performance highlights can be summarized as follow: line speed from 1 to 30 m/min; rubber capacity of 1000 kg/h; calendered width from 400 to 600 mm; ffabric thickness from 0.65 to 1.6 mm; steel cord thickness from 0.85 to 3 mm; precise humidity control at inlet/outlet; roll temperature from 50 to 90 °C. These specifications meet the demanding requirements of modern tire R&D. Moreover Miniduplex is fully aligned with Comerio Ercole’s Smartfactor strategy: MES integration; data collection packages; remote support; 360° 1monitoring of performance parameters; a new integrated full telemetry system to continuously monitor process parameters and machine performance; new AI-based support system.

With Miniduplex, Comerio Ercole delivers a compact, flexible, and high-precision calendering platform that accelerates innovation while reducing operational constraints. Whether used as an R&D tool, a pilot production line, or a mobile containerized solution, Miniduplex is an essential asset for tire manufacturers.