Stewarts of America manufactures and supplies a variety of anvil rolls, brush rolls, grooved rolls, felt covered rolls, urethane rolls, and idler rolls for industrial applications.

Brush Rolls

"Superdense" brushes are unlike any regular brush you can envision - They are specially designed for perforating applications, with "superdense" bristle density.

Multi-wall bag and plastic web manufacturers are replacing urethane and felt roller with superdense brush rollers. Superdense brush innovation has improved the process of pin perforating, slit perforating and slitting plastic webs and board products dramatically. Two materials are typically used for perforating, Tampico fibers for hot perforating because of tampico's high temperature resistance, and Nylon for cold perforating, slitting or any other operation at room or low temperature. Positives of this technology is that the brushes extend pin life dramatically over a urethane, silicone or rubber covered roller, as the bristles deflect from the pin tips when penetrated. These bristles move together and provide a solid surface for the web. Another benefit is that it does not matter where the pins engage the brush roller. The brush can accept the pins or blades any location. This reduces setup time dramatically. It is important to note however, that the brush fibers can liberate from the roller, however, so it is important that the user has particle detection equipment downstream of the brush roller.

Superdense brushes offer:

• Superior slitting and perforation quality
• Kind to materials
• Bristles accept pins or blades without with little to no bristle damage
• Dramatically reduces setup and changeover times
• Adjusting the anvil roller to suit the perf roll or blade is completely eliminated, making misalignment impossible
• Excellent web support
• Economical
• Increases pin and blade life dramatically
• Brushes are recoverable

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Grooved Rolls

Machined to match/mate up with the pins or blades that are being used. Grooves can vary in width and depth, and must be precision CNC machined in order to match up precisely with the perforating roll. Grooved rollers can be supplied as metal, urethane covered, silicone covered or rubber covered. Positives to grooved rollers are the fact that the pins are essentially in air, there is nothing to wear the pin. Drawbacks are that thinner materials can deflect off the pin tip and cause variation in hole sizes. One also has to mate the pins or blades up to the grooves precisely in order to prevent damage to the pins or blades. Grooved roller do not release particles, however, only work for low perforation density applications.
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Felt Covered Rolls

Felt covered rollers can be used for both hot and cold perforating applications, and are an inexpensive solution as a backup anvil roller.

Positives of felt technology is that felt rollers have great chemical resistance properties, excellent abrasion resistance, and its decent temperature resistance. Drawbacks are that the surface of the roller is not accurate enough for fine perforating. Note that covered rollers can particulate, so it is recommended that the user have particulate detection systems downstream of the rollers.
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Urethane, Rubber and Silicone Covered Rolls

Covered rollers can be a great solution to your perforating application.

Positives or covered rollers can be re-covered when they wear and can be used in a wide variety of perforating applications. Covered rollers are generally only good for fine perforating applications however, as the surface of the roller has to be soft enough to accept the pin, but hard enough to resist the picking action of the pin. Note that covered rollers can particulate, so it is recommended that the user have particulate detection systems downstream of the rollers.

5 durometer shore A up to 90 shore D hardness available with grooving, spiral ruling, spreader, diamond threading and crowning capabilities.
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Idler Rolls

Stewarts of America manufactures and supplies a variety of anvil rolls, brush rolls, grooved rolls, felt covered rolls, urethane rolls, and idler rolls for industrial applications.

Stewarts of America also offer high wearing coatings such as chrome, tungsten carbide and ceramic, and high release coatings such as fluoro-polymers, and protective roll covers.

Stewarts of America manufactures lightweight idler rollers with internal or external bearings. Idlers can be made with grooves going in the machine direction or the cross web direction for air ventilation, which allows the web to lay flat on the roller to help resist wrinkling and air trappage.
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Industrial Sponge Rolls

Stewarts of America offer industrial sponge rollers in three colors:

• Gray Sponge - for applying solvent stain on smooth, hand scraped, or beveled substrates.
• Red Sponge - this compound is designed to allow the stain to ride on the surface of the sponge and release on to the surface of wood and other porous materials.
• Blue Sponge - the latest generation of sponge material developed as a hybrid roller. This sponge is resistant to solvents, water based AND 100% UV stains and other liquids. This special compound is designed to allow the liquid to penetrate into the sponge before being squeezed onto the surface of the product.
• The thickness and porosity of any of these sponge coatings can be varied to suit application requirements.

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Industrial Raising Fillet Rolls & Tools

Stewarts of America offer raising fillet rollers, also known as flexible card clothing, metallic card clothing, yarn raising fillet, velvet fillet, wool fillet, fancy fillet, tiger fillet, carrier fillet or scattering fillet.

Round or square wires, in bright, galvanized, tinned or stainless steel finishes. Fillet bases can be made from red rubber, cushion rubber, felt or leather. Chisel, sharp taper, pointed or mushroom style tips. Fillet rollers can be used for a number of texturing, finishing, cleaning and perforating applications. Stewarts of America also make hand tooling from raising fillet for the textile industry.
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