On August 1 and 2, operators of all kinds that use calendering lines for the processing of PVC - and not just that - were invited to the facilities of Rodolfo Comerio in Solbiate Olona (Varese), where they had the opportunity to “gasp” both at the impressive bulk of a gigantic five-roll calender (each roll having a diameter of 870 mm and a length of 5000 mm on the table, or 8000 mm if we also consider the cylinder pins), and also at the mighty 32,000 kg shoulders being finished for an equally enormous calender, which, however, has “only” four rolls (each, again, 870 mm in diameter, 8000 mm in length and weighing 25,000 kg).

“These two gigantic calenders, which we have we have developed and built ad hoc for the lamination of thermoplastic resins and for the coupling of special materials, will have their official world premiere at the K fair in Düsseldorf, but the presentation will only consist of visual simulations, 3D movies, and photographs showing the various construction phases. After all, we are talking about machines whose shipment to the end customer will require more than 60 containers”, explained Nicola Fedele, sales director at Rodolfo Comerio.

It is obvious, therefore, that the aim of this open house event, held just a few weeks before the Düsseldorf fair, was to give customers (both existing and/or potential ones) a chance to see for themselves the biggest calenders for plastics ever made, and also to appreciate the skill with which the machine shop personnel at Rodolfo Comerio tackle the mechanical processing of the structural parts, and the expertise with which the company’s technicians install the most sophisticated roll-bending and cross-axis systems, designed to guarantee, over time, the geometrical and performance consistency of laminated goods.

“Düsseldorf is an important showcase and it is also the place where we will be giving the international technical press an account of – how can I put this? – all the records that we, as a company, have set. First of all, there is the fact that the five-cylinder calender featured at the open house boasts the new world record for size, and what is more we are the holders of the previous record, too”, remarked Nicola Fedele.

“We will also be sharing some details of a very recent order we have received whose value, in economic terms, is also “impressive”. It is worth 27 million euros, and has been placed by a single customer from the US. In Germany we will also be giving some details of a  patent for precision embossing which can now be carried out at the same time as the printing during the calendering of faux wood flooring: so-called LVT”, Fedele continued.

Last, in order of presentation but certainly not importance, is a technological “gem” that Nicola Fedele also mentioned, remarking: “The application setting is tyre manufacturing. In October the formal procedures for obtaining the international patent coverage will not have been completed, therefore at K we will be giving only a foretaste of some of the specifications for an ultra-new calendering method that is destined to revolutionise the sector”. Basically, if you want to know more you will simply have to make your way over to the Rodolfo Comerio stand in Germany.

(Top photo: This photograph, showing some of the Rodolfo Comerio staff members who organised and took part in the open house event, pictured alongside one of the two calenders, gives an idea of the true dimensions of the machine; middle photo: a cylinder being mounted on one of the mammoth calenders; bottom photo: one of the two gigantic calenders exhibited at the open house event)