The Industrial Brush Company is a trusted supplier to customers in the film converting industry because of our unique brush construction, partnerships, and expertise. The industry term for these brushes is “backup brush.” Backup brushes have increased productivity in a wide range of applications, replacing metal and rubber covered anvil rollers used for conventional razor slitting, hot and cold pin perforating, and web tensioning applications. Film converters using backup brushes have reported superior slitting and perforating quality along with increased blade and pin life while also reducing set up time. Backup brushes are also being used in web handling applications as air relief rollers, wrinkle removal devices and spreader-rollers. They can be an effective means of improving web tracking, web tensioning and web flatness on a wide range of products. Our patented Fineset technology creates a better brush the will not scratch the web and allows for greater variability of design, meaning our brushes are truly tailor-made to meet the exact needs of our customers.
Slitting to WidtH
Back Up Brush Razor Slitting
Fineset brushes epoxy bond nylon bristles onto a core in a way that allows each filament to act individually to support the web. Nylon is the most common filament choice for this application due to its uniformity, bend recovery, and fatigue resistance properties. Filament diameter and bristle length can also be varied to achieve just the right support for even the most fragile webs. The individual bristles easily move out of the way of the razor and maintain maximum web support because each bristle moves as a single filament. Set up time is drastically reduced not having to align blades between grooves in steel anvil rolls. Back Up Brushes result in a a cleaner cut with longer blade and brush life. The fatigue resistance of the nylon paired with Fineset bonding technology makes for a brush that will last longer with better results than other options.
putting holes in a web
Backup Brushes for Pin Perforating
Fineset brushes epoxy bond bristles onto a core in a way that allows each filament to act individually to support the web. Nylon is commonly chosen for cold pin perforating due to its uniformity, bend recovery, and fatigue resistance properties, as well as the diameter availabilities. Tampico fibers are used for hot-pin perforating because of its heat resistance and stiffness. Tampico is a natural vegetable fiber that can withstand temperatures peak temperatures in excess of 600°F. Normal conditions for hot-pin perforating see the pins reach temperatures ranging from 150°F to 600°F (66 to 315°C). Perforating pins penetrate the brush and individual bristles easily move out of the way to maintain maximum web support. The need to align male pin rollers with female anvil rollers is is eliminated reducing set up time. The result is a cleaner perforation with longer pin and brush life. The filament properties paired with Fineset bonding technology makes for a brush that will last longer with better results than other options. Backup brushes make expensive anvil rollers pointless and mean that only the web will get the point of the pin roller.
Film manufactures, paper board manufactures, and converters, printers, and laminators of various web products use backup brushes as web handling devices. They are being installed as tensioning devices to improve web tracking and web flatness. Backup brushes are replacing conventional metal idler rollers, grooved rollers, diamond knurled rollers, and spreader rollers. Backup brushes used for tensioning are typically installed just before a converting, printing, coating, or laminating operation to help ensure web flatness. Tensioning brushes create improvements in web handling control and web flatness due to reductions in web slippage, web alignment, air entrapment, hard wrinkles, and a reduction in web looseness. Tensioning brushes are also an effective means of helping web stabilization as the last set of rollers to create a consistent web prior to rewind.