When rapid changeovers are critical to maintaining uninterrupted production, precision engineering and dependable safety components make all the difference. A large-scale laminating unit developed by SAUERESSIG demonstrates how advanced rail brake technology enables fast and efficient roller replacement while supporting continuous 24/7 operations.
Originally established nearly 70 years ago as a manufacturer of printing and embossing rollers for the packaging and printing industries, SAUERESSIG has grown into a forward-looking mechanical engineering specialist with a broad portfolio. Today, the company delivers complete calendering, embossing and rotary processing systems, offering both standard and custom-built solutions. Its expertise spans the full project lifecycle — from concept development and mechanical design to drive and automation technology, pre-assembly, commissioning and final acceptance at the customer’s site.
One example of its customised solutions is a laminating system measuring approximately six metres in length and four metres in width. The unit coats both sides of a vertically guided steel strip with a thin protective PET film at conveying speeds of up to 250 metres per minute. The process relies on two symmetrically arranged laminating assemblies, each equipped with a rubber-coated laminating roller and a water-cooled contact roller. While the laminating rollers press the protective film onto steel heated to temperatures of up to 260°C, the cooling rollers regulate the rubber surface temperature to a maximum of 90°C.
Despite effective cooling, the rubber linings are subject to wear and require periodic replacement. To minimise downtime, the system has been engineered for automated roller changeovers completed in around 30 minutes. Each side frame is mounted on profiled rail guides, allowing the machine halves to separate axially for maintenance access.
Four profiled rail brakes from the ROBA guidestop series, supplied by mayr power transmission, hold the laminating assemblies securely in position during operation. These fail-safe brakes clamp directly onto the profiled rails using pre-tensioned springs and release hydraulically at a nominal pressure of 70 bar. Designed with generous stroke tolerances and dual independent brake circuits, they provide high holding forces, rigidity and redundancy.
By mounting directly onto the moving masses, the brakes eliminate backlash and enhance safety, particularly on gravity-loaded axes. Available in hydraulic, pneumatic and customised electromagnetic versions, the ROBA guidestop range supports a wide variety of linear guide systems.
Founded in 1897, mayr power transmission is a global supplier of safety brakes, torque limiters and shaft couplings, serving industries ranging from machine tools and packaging to wind energy and stage technology, with operations spanning more than 60 countries worldwide.
