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Aluminum Rollers

Aluminum idler rollers have an exceptionally wide range of uses for multiple web guiding applications. At the same time, these durable products are about half the weight of steel idlers. This type of idler roller is best suited for web guide applications with low web tensions and less web material. We offer both dead shaft and live shaft aluminum idler rollers. Both types can be customized with air entrainment grooves, hard coat anodizing, cantilevering, bearings inserts, and cork, plasma, and rubber coverings.

Today, we engineer aluminum idlers for a wide range of converting applications. Each roller is designed to meet the exact specifications of its intended use. These idlers provide exceptional performance over a wider range of applications while possessing nearly half the weight of steel. These lighter idlers are ideal for applications requiring lower web tensions and minimal web wrap. Low friction ER Style bearings for dead shaft rolls.

Dead Shaft Aluminum Idler Rolls

  • 6061-T6 aluminum tubing machined for minimal stock removal
  • 32 Ra finish on roll face
  • Dynamically balanced to ISO grade G6,3
  • Straightness over roller face width within the greater of 0.002 in. or 0.0005 in/ft of face length
  • Low-Friction bearings

Live Shaft Aluminum Idler Rolls

  • 6061-T6 aluminum tubing machined for minimal stock removal
  • 32 Ra finish on roll face
  • Dynamically balanced to ISO grade G6,3
  • Straightness over roller face width within the greater of 0.002 in. or 0.0005 in/ft of face length
  • Journal Material 1018 Carbon Steel
  • Journal run out to roll O.D. within 0.003 in.

Live Shaft vs. Dead Shaft Aluminum Idlers:

If you have decided to go with an aluminum idler, another decision you will need to make is if you want live shaft or dead shaft.  Each has their key advantages and the decision depends solely on your unique manufacturing requirements.

  •  Dead Shaft
    Dead shaft aluminum idlers are less expensive than live shaft idlers, which has made them more popular over the years.  Also, since the roll body is the only rotating object on a dead shaft idler, the rolling inertia is much less than a live shaft.  Dead shaft idlers also benefit by having low friction bearings, which help increase the bearing life span.
  •  Live Shaft
    The most popular reason people go with live shaft idlers is because they can work in harsher environments like those that involve damaging chemicals or vapors, high levels of dust, or excessive moisture.  Also, since the bearing size is not limited to the size of the idler roll body, live shaft idlers can withstand higher workloads.  Another key advantage of live shaft rollers is that they can allow for longer rolls since self-aligning bearings can be used. Live shaft idlers can also work in elevated temperatures when positioning the bearings outside the harsh environment which prolongs the bearing life.

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