Innovative Solutions for Metals Processing Technology

Innovative Solutions for
Metals Processing Technology
Brush Rolls
Equipment & Systems
Non-woven Rolls
Members of Jason Finishing Group

Mission statement
With the ability to connect, in the most customer
friendly way, global competence with
extensive local service, we develop and manufacture
innovative quality products and solutions,
targeted for machine system engineering
and operations with rolling mills and strip
processing line technology.
Reliability and sustainability in terms of our
customers, employees and company determine
our actions. At the same time, the principle
of responsible and careful management
of our environment and its natural resources
continue to direct our operations.
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Content
1
Introduction Page 3
2
Brush roll applications
2.1 Degreasing, washing and cleaning Page 5
2.2 Activation of strip surface Page 7
2.3 Roll cleaning and polishing Page 8
2.4 Strip polishing and finishing Page 9
2.5 Scale removal Page 11
2.6 Roll coating control Page 13
2.7 Transport roll systems for HHT furnaces Page 15
2.8 Transport roll systems for high temp applications Page 17
2.9 Transport roll systems for noise reduction Page 18
3
Brush roll systems
3.1 Complete brush roll systems Page 19
3.2 Factory Assembly (FA) brush roll systems (Integrated Maintenance Service) Page 21
3.3 Customer Assembly (CA) brush roll systems Page 23
3.4 OSBORN HDL ® brush rolls Page 25
3.5 Lipprite ® abrasive non-woven rolls Page 27
4
NOVOTEX ® non-woven rolls Page 29
5
Innovative equipment technology
5.1 Vacuum squeezing systems Page 35
5.2 Brushing equipment for strip processing lines Page 37
6
Load Runners ® - Idler rollers and load rails Page 39
7
Fill materials Page 41
8
Technical information Page 43
9
Our further product range Page 45
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1
OSBORN International
Your competent partner in surface finishing solutions - worldwide
Companies all over the world rely on the quality and efficiency
of OSBORN. With a total of twelve sites, high quality
tools are developed and manufactured for processing surfaces
for use in a variety of sectors in industry.
close complex service network of the other OSBORN businesses,
branch offices and local service partners, provide a
comprehensive service for our customers’ rollers anywhere
in the world.
Specialised technology centres in our factories in Germany,
England, Sweden, the USA, Brazil and China as well as a
Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
* OSBORN International GmbH
Ringstraße 10
35099 Burgwald - Germany
Phone: ++49 (64 51) 5 88-0
Fax: ++49 (64 51) 5 88-206
eMail: info@osborn.de
Lippert Unipol GmbH
Eschelbronner Straße 35
74925 Epfenbach - Germany
Phone: ++49 (72 36) 91 24-0
Fax: ++49 (72 36) 91 24-91
eMail: sales.lippert@lippert-unipol.de
Lippert Unipol GmbH
Rudolf-Harbig-Weg 10
42781 Haan - Germany
Phone: ++49 (21 29) 93 07-0
Fax: ++49 (21 29) 93 07-23
eMail: sales.lippert@lippert-unipol.de
* OSBORN Unipol Ltd.
Lower Church Street
Chepstow, Monmouthshire NP16 5XT - UK
Phone: ++44 (12 91) 63 40 00
Fax: ++44 (12 91) 63 40 98
eMail: sales@osborn-unipol.co.uk
* OSBORN Unipol S.A.
Parc d’Activités Les Doucettes
23, Avenue des Morillons
95140 Garges Lés Gonesse - France
Phone: ++33 (01) 34 45 06 00
Fax: ++33 (01) 39 93 67 11
eMail: info@osborn.fr
OSBORN Unipol S.A.
Parc d’Activités de la Fringale
27100 Val de Reuil - France
Phone: ++33 (2) 32 09 50 50
Fax: ++33 (2) 32 25 06 92
eMail: contact@lippert-unipol.fr
* OSBORN International AB
*
Huskvarnavägen 105
S-56123 Huskvarna - Sweden
Phone: ++46 (36) 38 92 00
Fax: ++46 (36) 14 43 49
eMail: info@osborn.se
OSBORN International A/S
Nr. Bjertvej 103-107
6000 Kolding - Denmark
Phone: ++45 (76) 32 76 32
Fax: ++45 (76) 32 76 00
eMail: info@osborn.dk
OSBORN Unipol S.L.
Ronda Norte, 320
Poligono Industrial
46470 Catarroja (Valencia) - Spain
Phone: ++34 (961) 325 876
Fax: ++34 (961) 324 602
eMail: ventas@osborn-unipol.es
OSBORN Unipol Lda.
Lugar da Cruz-Brito
4800 Guimarães - Portugal
Phone: ++351 (253) 47 95 50
Fax: ++351 (253) 57 66 29
eMail: sales@osborn-unipol.pt
OSBORN International S.R.L.
Bd. Bucovina F.N.
725300 Gura Humorului - Romania
Phone: ++40 (230) 234 212
Fax: ++40 (230) 531 785
eMail: rosales@osborn.com
OSBORN International Ltda.
Rua Lemos Torres, 150, Jardim Galiardi
09890-070 Sao Bernado do Campo - Brazil
Phone: ++55 (11) 43 91 65 59
Fax: ++55 (11) 43 91 65 50
eMail: osborn@osborn.com.br
OSBORN Lippert India Pvt.Ltd.
Plot No. E-66, MIDC Waluj
Aurangabad - 431 136 - India
Phone: ++91 (2 40) 25 56 53 8
Fax: ++91 (2 40) 25 52 53 0
eMail: sales@osborn-lippert.co.in
* OSBORN International China
Rm. 505, Tower H, Huiyuan Int. Apartment
No. 8 Beichen East Road, Chaonyang District
Beijing 100101 - PR China
Phone: ++86 (10) 84 98 81 91
Fax: ++86 (10) 64 99 18 63
eMail: cnsales@osborn.com
* OSBORN International
5401 Hamilton Avenue
Cleveland, OH 44114-3997 - USA
Phone: ++1 (800) 720 33 58
Fax: ++1 (216) 361 19 13
eMail: brushes@osborn.com
For further contact details worldwide: www.metallurgy-brush.com
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* Centers of excellence for brush rolls!

High quality raw materials, years of experience, modern manufacturing
techniques, and careful workmanship. These are
important criteria which ensure the consistently high quality
of OSBORN products. Quality assurance accompanies all
stages of production. It is fully integrated into the processes
and certified in accordance with DIN EN ISO 9001-2000. This
has made us the world’s #1 supplier in brush technology, but
we are not satisfied with that. Constant innovation and product
development are of central importance to us, both inhouse
and in close cooperation with technology partners in
Europe, Asia and North America. We seize the goal of making
our range of services, and with it the products and processes
of our customers, better, faster, safer, more reliable and more
environmentally friendly.
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2.1
Brush roll applications
Degreasing, washing and cleaning
The demands relating to the quality and the technical product
characteristics of flat rolled steel in the form of cold
rolled steel, tin plated steel, electrical steel, galvanized strips
or other refined surface materials are steadily rising. Along
with increasing processing speeds, optimising the tempering,
refinement or coating process of the upstream strip
cleaning section also increases.
comparison to conventional brush rollers. HDL ® sets new
standards in the degreasing and cleaning of strip surfaces.
Through the consistent development of quality, by looking
at fill material, brush construction and fill density, we
achieve significant improvements in terms of the brush lifetime
/ cleaning performance. This results in reduced operating
and maintenance costs for our customers.
With the development and introduction of the HDL ® brush
roller, OSBORN has found an answer to these demands, in
Application category Metallurgic field Process line Description of application OSBORN product range
Degreasing, washing
and cleaning
Carbon steel
Stainless steel
Aluminium
Non ferrous
CGL, CAL, CL/ DL, ETL
CCL, CAPL, BAL, CL
TLL, SL/ CCL
CL, DPL, APL, CPL
Removal of oil, grease, other
protective coatings, rolling
residues or dirt from the
strip/sheet surface
Brush rolls, abrasive or nonabrasive,
OSBORN HDL ®
Technology
OSBORN HDL ®
- a new benchmark in strip cleaning
Customers’ needs depend on the type and degree of soiling
of the primary material as well as on the strip cleanliness
required for the subsequent process step. While optimum
degreasing and micro-cleaning may be achieved with nonabrasive
multi-filaments, abrasive filaments are ideally suited
for the removal of strongly adhesive rolling retentions from
the previous rolling process.
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OSBORN HDL ® brush rollers are therefore individually tailored
to the relevant case in hand. At the same time, multi-filaments
and special mono-filaments can be used with or without
an abrasive load as single bristle or mixture filaments.

Besides brush rollers for degreasing and cleaning applications,
OSBORN offers a series of other innovative products
and solutions for cleaning sections of strip lines:
• LOAD RUNNERS ® ensure a durable and maintenance-free
function of roll exchange vehicles.
• Temperature and alkaline resistant brush seals provide
optimum splash protection on the strip inlet and outlet of
individual machine elements.
• Vacuum squeezing systems set new standards in the complete
drying of strip edges. It is possible to replace the hot
air dryer altogether, resulting in enormous energy savings.
• In the modernisation of strip lines, it is possible, through the
integration of optimised brush machines instead of the old
line, to create additional space for further improvements to
the line. This is achieved by the compact design as well as an
improvement in cleaning efficiency.
• NOVOTEX ® squeezing rollers complete the OSBORN strip
cleaning range. Compared to conventional rubber or
polyurethane rollers, these non-woven rolls offer a number
of beneficial product characteristics, such as significantly
better coefficients of friction, material compression or cut
and wear resistance. This in turn ensures longer durability,
improved squeezing results, prevention of aquaplaning
and reduction of damage to the strip.
OSBORN innovations for cleaning sections in strip processing lines
Alkaline brush
cleaning
Squeezing
rolls
Brush cleaning
Squeezing
rolls
Squeezing
rolls
OSBORN HDL ® NOVOTEX ® OSBORN HDL ® NOVOTEX ® NOVOTEX ®
Load Runners ®
Brush seals
Alkaline spray
cleaning
Electrolytic
cleaning
Water rinsing
Hot air dryer
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2.2
Brush roll applications
Activation of strip surface
The activation of the strip surface is an important task both
in the production of rolled claddings as well as in the coating
and/or finishing of strip steel, tinplate, electrical steel
strip and other materials. In rolled cladding, the core and, if
necessary, the overlay strips or plates have to be freed initially
from oil, grease, dirt, carbon particles and oxides. This
is done with the help of brush rollers in alkaline cleaning or
acidic pickling processes.
In the next process step, an activation of surfaces then takes
place by generating a defined roughness using abrasive or
wire brushes. A similar process also happens in continuous
strip coating. In both cases, an optimal adhesion is guaranteed
for the subsequent rolled cladding and/or organic or
metallic coating through surface activation.
Application category Metallurgic field Process line Description of application OSBORN product range
Activation of strip surface
Carbon steel
Aluminium
Non ferrous
CGL, CCL, EGL, ETL
CM
APL, CPL
Strip surface activation
prior to coating
Strip, sheet or plate surface
preparation prior to cladding,
coating or pressing
Brush rolls, abrasive or wirefilled,
OSBORN HDL ®
Technology
OSBORN HDL ®
- micro cleaning plus surface activation
Here too, HDL ® rollers from OSBORN create an ideal combination
of the different brush functions needed by our customers.
The non-abrasive multi-filaments ensure optimum
micro-cleaning as the abrasive filament mechanically intensifies
its abrasive effect and at the same time generates the
required surface activation. The grinding agent, grain size,
face density and abrasive content are also individually adjusted
to the respective individual application.
OSBORN has devoted itself to this challenge for years. We
have strategically maneuvered ourselves to be the premier
producer of brush rollers through the development of innovative
microfilaments and brush constructions as well as the
preservation of high quality standards.
In steel sheet coating, the brush roller has long been promoted
as an absolute high-performance and precision tool in the
case of thicknesses of < 0.15 mm, coating thicknesses of 0.05
g/m² and even higher line speeds. At the same time, the individual
demands made on the brush depend on the flatness,
surface hardness of the starting material and the nature of the
subsequent coating or plating.
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Brush roll applications
Roll cleaning and polishing 2.3
OSBORN’s Helimaster brush rolls are perfect for cleaning
work and as back-up rolls in wet or dry operated rolling and
skin-pass mills. They have been fitted to technological developments
worldwide for decades, both in online lines integrated
in strip lines as well as stand-alone off-line rolling
stands.
The rollers can work sporadically or continuously when
designed as a wire or an abrasive brush. Each brush is neutrally
ground at the radius and gets axially. This means that it
gets either a cylindrical camber ground or, for offsetting the
computed roll deflection, a positive and/or negative camber
ground.
In the meantime, with Lipprite ® abrasive rollers, an alternative
technology, has also been developed and manufactured inhouse
for skin-pass roller cleaning.
Application category Metallurgic field Process line Description of application OSBORN product range
Roll cleaning and polishing
Carbon steel
Stainless steel
Aluminium
SPM, TM, CGL
SPM, TM
CRM
Removal of oxides, dirt
and rolling residuals
Helimaster ® Brush rolls, abrasive
or wire-filled; Non-abrasive
Brush rolls; Lipprite ®
abrasive non-woven rolls
The brush roller itself is only part of
the solution. This technologically demanding
application can only be optimally implemented with a precise
matching of the brush tool to operational and process parameters.
The reproducibility of the specified corrosiveness and
brush effect as well as constant tool performance play a crucial
role from the first point of use to the exchanging of the
roller.
Roll cleaning in a typical skin-pass mill
For the cleaning of deflector, shape control or thickness measurement
rolls, special wear-resistant non-abrasive plastic filaments
are used. They ensure an equally thorough removal of
solids and liquid materials without damaging the roll surface
or altering the roughness. At the same time, the filament type
and bristle diameter are dependent on the surface hardness
and the degree of pollution of the roll that requires cleaning.
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2.4
Brush roll applications
Strip polishing and finishing
When it comes to the optical finishing of strip surfaces in
the form of polishing, satinising, finishing or decorative
grinding and brushing, you’re in good hands with OSBORN.
Decades of experience in the machining of steel, stainless
steel, aluminium and other non-ferrous surfaces have given
us a technological advantage, from which our customers
benefit worldwide today.
In addition to high-quality wire and abrasive brushes, we
can also rely on a merger with the Lippert-Unipol Group,
one of the global leaders in abrasive and polishing tools, if
necessary. We can combine polishing and abrasive rollers
as well as polishing compounds on a selection / combination
of tools and processing alternatives. This is unique in
the market, which gives you the advantage of the most
optimal surface finishing in your application.
Application category Metallurgic field Process line Description of application OSBORN product range
Strip polishing and finishing
Carbon steel
Stainless steel
Aluminium
Non ferrous
PL, APL , FL
Oxide removal, polishing
and finishing of hardened
and tempered strips
Oxide removal, polishing,
finishing and generating
decorative surfaces
Brush rolls abrasive or wirefilled;
Bessemer-wire brush
rolls; OSBORN HDL ®
Technology; Lipprite ® abrasive
non-woven rolls; UNI-
POL ® polishing emulsion
Today, increasingly higher demands are made on the final
machining of strips. An optically perfect and homogeneous
surface over an entire field of vision achieved through the correction
of small surface defects in the last mechanical machining
step is in high demand. This applies equally to the operators
of strip lines as well as for service centres or direct
processors of coils.
Different types of rollers and coatings can also be used
depending on the material type and quality, the surface hardness
and the required finish and condition before the final finishing.
For determining the respective optimum tool, we
carry out individual pilot tests at test lines in our laboratory.
9

A combination of Bessemer wire roller brushes and polishing
emulsions is used in the removal of oxide layers and polishing
cold rolled uncoated strips after annealing re-crystallisation.
Both components come from OSBORN-UNIPOL and are
specifically matched to individual surface requirements.
All-in-one solution made by OSBORN-UNIPOL
Polishing station with
Bessemer wire brush rolls
UNIPOL ® polishing emulsion
(liquid emulsion application)
UNIPOL ® polishing emulsions are initially applied directly to
the strip surface to be processed as a liquid paste in immersion
baths or by means of a low-pressure, medium-pressure,
high-pressure or airless spraying system.
With Bessemer wire measuring diameters of 0.06 or 0.08 mm,
filled rollers serve as carriers of this paste in the subsequent
polishing process.
Our Lipprite ® product series represents an alternative to
brush rollers with a wire or abrasive bristle coating. As with
grinding non-woven rollers, an absolutely uniform fine final
grind and a corresponding homogeneous surface finish can
be achieved. With the correct contact pressure, the flexible
roller surface is in a position similar to a brush to offset any
slight unevenness of the strip.
Lipprite ® abrasive non-woven rolls for a perfect surface finish
10

2.5
Brush roll applications
Scale removal
For de-scaling strip surfaces after hot and cold mill processes,
our brush rollers have been setting standards for years.
OSBORN’s developments and innovations in both brush constructions
and filaments have in set the international standards
in annealing and pickling lines or bright annealing lines
for stainless steel strip.
With the development of acid resistant fill materials, it has
been possible to achieve tremendous quality and improvements
relating to service life on numerous strip lines. This
results in substantial reduction of total cost for our customer.
The parallel optimisation of the brush / shaft design and operational
parameters through targeted assistance on site is
another important OSBORN competence based on our longstanding
worldwide experience.
Give us a challenge!
Application category Metallurgic field Process line Description of application OSBORN product range
Scale removal
Carbon steel
Stainless steel
Non ferrous
CPL
HAPL
HAPL
HRM
Heavy duty descaling prior
to acid pickling
Heavy duty descaling between acid tanks
Scale and dirt removal prior to rolling
Brush rolls abrasive or wirefilled;
Heavy abrasive brush
rolls; OSBORN HDL ®
Technology; Lipprite ® abrasive
non-woven rolls
A new brush-generation - acid proof filaments
Through the development of special abrasive and non-abrasive
facing materials combined with an improved level of acid
resistance and excellent wearing properties, the lifetime of
brush rollers in stainless steel strip lines has now been significantly
increased. This allows tremendous cost savings in
the form of longer lifetimes and lower maintenance costs.
Ideally, the abrasive rollers are inserted on roller systems
made from hollow shafts with bore holes. Apart from
improved cooling of the filaments in the continuous operation
of the roller, these also provide continuous rinsing out of
acid or other corrosive mediums from the brush lining. An
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optimum rinse function is ensured on one hand by the correct
number and size of the cooling holes and on the other hand
by the amount of liquid.
At the downstream strip drying operation, similarly significant
process improvements and substantial cost savings can
be achieved through the use of squeezing rollers, which are
made of newly developed, acid-resistant, non-woven materials
or through the use of vacuum systems.

Where stainless steel materials reach their limits in high acid
concentrations, special protective coatings on shafts and
accessories provide the optimal protection of these components.
In addition, steel shafts with shock and impact resistant coatings
provide cost benefits as they are an interesting alternative
to stainless steel bodies.
In manufacturing stainless steel flat products, OSBORN
International’s intelligent solutions and innovations play a
part in process optimisation and quality improvement as well.
Our solutions are deployed for de-scaling hot and cold mill
strip surfaces at many levels of the value chain:
• HDL ® brush rollers with a micro-fibre brush for careful and
thorough cleaning of sensitive strip surfaces
• Acid and temperature resistant brush sealings
• Lipprite ® abrasive rollers for surface finishing and follow-up
processing plates and strips
• NOVOTEX ® squeezing rollers with an acid resistant nonwoven
covering
• Braking, tension, deflection or pressure rollers made from a
non-woven covering for replacing rubber or polyurethane
rollers
• Helimaster brush rollers for cleaning rolls in skin pass mills
• Vacuum squeezing roll systems as an energy-saving replacement
of strip dryer
• High temperature brush transport rolls for hot and cold strip
on continuous furnace lines
• Brush transportation rolls for reducing noise on slitting and
cross-cutting lines for heavy plates
• LOAD RUNNERS ® heavy load rolls in coil transportation
devices or roll exchange vehicles.
Process chain of stainless steel flat products manufacturing
Steel mill Hot rolling mill Pickling line
Cold rolling mill
Annealing and pickling line
Annealing and pickling line
Bright anealing line
Stretch levelling line
Stretch levelling line
Slitting line
Cross cutting line
Hot strip Cold strip
Slab Wide strip Wide strip Slit coil Blanks Wide strip Slit coil Blanks
12

2.6
Brush roll applications
Roll coating control
Almost 50 years ago, OSBORN developed a revolutionary
technology using brushes in the continuous rolling process
in order to optimally regulate the oxide film on working and
back-up rollers in hot rolling mills. As a result hundreds of
hot mills worldwide have been equipped with OSBORN
technology.
To date, specially designed wire qualities, abrasive multifilaments,
individually camber ground surfaces and extensive
experience in optimising the use of brushes in numerous
individual applications have secured a major technological
advantage for us in this field. The benfits from this
we can pass on to our customers worldwide.
Application category Metallurgic field Process line Description of application OSBORN product range
Roll coating control
Aluminium
Non ferrous
HRM, HRFM, HFM
HCM
Control of the oxide layer
and removal of oxides
Helimaster ® Brush rolls
abrasive or wire-filled
Lateral rings made of composite fibre materials for limiting
immersion depth and sleeves for splash guarding journals
and bearings - developments created by OSBORN.
On hard chrome working rollers, abrasive multi-filaments
with a high density achieve a particularly uniform brushing
and cleaning of roll surfaces.
13

The individually adapted camber ground of the brush roller
body is one of the most important prerequisites for guaranteeing
uniform brushing across the entire width of the
roll. Depending on the construction of the working or backup
rollers to be brushed and the calculation of the optimum
crown, convex or concave contours are ground. OSBORN,
of course, also grinds brush rollers with a CVC contour on
CVC technology mills for roller gap adjustment.
Precision camber ground for optimum brushing results
14

2.7
Brush roll applications
Transport roll systems for HHT furnaces
The tempering of hot mill plates made of precipitation hardening
aluminium alloys through the process of solution
annealing, serves the purpose of attaining higher strength
and strain values along with a good level of corrosion resistance.
Today, this is required for structural parts in aircraft in
accordance with the strict requirements of standards AMS
2750D, AMS 2750C and AMS-H-6088.
The careful transportation of these aluminium plates in ‘hard
metal and hard material technology’ roll hearth furnaces
takes place as a batch or continuous process at temperatures
of up to 600°C on brush transportation rolls. In close cooperation
with leading equipment manufacturers, numerous furnaces
around the world have been equipped in recent years
with OSBORN’s sophisticated technology. In the process,
plates with thicknesses of up to 400mm, lengths of 20 metres
and weights of over 10 tonnes do not present a problem for
us. Tolerances have been continually reduced and product
features optimised, so that now more than ever, the brush
roller is an integral and technologically superior component
in the overall design of the line.
Application category Metallurgic field Process line Description of application OSBORN product range
Transport roll systems for
HHT furnaces
Aluminium
HHT plate furnaces
Transportation of hot plates
through the heat treatment
process; optimized heat
transfer; Avoidance of transport
roll pick-up and surface
damages
Brush transport rolls; HHT
brush transport roll systems;
Furnace capacity increase
concepts
Surface-sparing plate tracking with longstanding roll lifetimes
With brush furnace transportation rolls, OSBORN customers
can today place their trust in several decades of experience
and well known global references. In the complex production
of the rolls, some with a total length of over 6000mm and
4000mm of brush length, the highest level of precision and
reliability are required in all manufacturing processes.
After the rolls have been manufactured, the later course of
the sheet is accurately simulated in advance in our factory.
For roll assemblies in new furnace lines, this allows OSBORN
15
to guarantee an optimum course of the sheet within tight tolerances
even when starting up the run.
In order to guarantee the lowest possible sheet tracking with
the ‘re-brushing’ of entire furnace zones the transportation of
the sheets is simulated on an in-house test rig just like new
lines.

This advanced technology provides a convincing argument
for why brushing with heat resistant wires is increasingly
establishing itself as a roller cover for furnace transportation
rolls.
• Optimum heat transfer between the transportation roll and
the plate
• Longstanding lifetime without significant wear of the brushes
• Complete avoidance of scale pick-up and spot formation
on the surface of the roller, just as it is the case with selfcontained
roller coverings
• Total-care transportation of the plates during the heat treatment
without damaging the surfaces of the plates
Aside from the production of new rolls, the recovering and
replacement of worn brushes in older lines is also one of our
core competences.
By precisely measuring the course of the plate as well as the
state of the individual rolls within the furnace by means of
self-developed test equipment, we are able to optimise plate
tracking if needed, which maximizes the output of the entire
system.
Capacity optimization at older furnace installations
Plate tracking in initial state
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
Plate tracking after optimization as per OSBORN recommendation
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5 Zone 6
16

2.8
Brush roll applications
Transport roll systems for high temp applications
Roll coverings made from extremely dense stainless steel
wires in special alloys and resistant to high temperatures provide
specific product features and strong advantages compared
to uncoated transportation shafts or furnace rollers
with ceramic coatings. These can be used in different horizontal
heat treatment lines for strips of steel, stainless steel or
non ferrous metals.
Application category Metallurgic field Process line Description of application OSBORN product range
Transport roll systems
for high temp
applications
Carbon steel
Stainless steel
Aluminium
Non ferrous
CAL, CGL
BAL, CAPL, CAL, HAPL Transportation of high temp strip;
Avoidance of transport roll pick-up
HHT
and surface damages
conveyor furnace
High temp brush transport
rolls; Brush transport roll
systems
Excellent brush lifetimes without scale pick-up up to 1100°C
Properties and Advatages
• Temperature resistance of up to approx. 1100°C
• Shaft construction with internal cooling
• Particularly careful transportation of the plates and reduction
of damage to the surface
• Very low wear to the rolls with significantly longer lifespan
than ceramic coatings or other roll coatings
• Extremely dense and accurate neutrally ground surface of
the rolls
• Significantly better heat transfer characteristics of the tips of
the wires in comparison to full metal surfaces
• No scale pick up (formation of spots) on account of the
absorption properties of the exposed brush surface
• Reduced maintenance
17

Brush roll applications
Transport roll systems for noise reduction 2.9
When transporting the sheets onto rolling tables, extreme
noise levels may occur in slitting/cross cutting lines by heavy
plates after the shearing process. At over 110 dB, this may
possibly exceed the threshold of noise pain for the human
ear.
By coating the bright transport rollers with brush sections,
the noise level can be reduced to around 70 dB so that any
health risk to the labor force is significantly reduced.
Application category Metallurgic field Process line Description of application OSBORN product range
Carbon steel
Transport roll systems
for noise reduction
Stainless steel
Aluminium
Non ferrous
SL, CCL, transport
roll tables
Low noise, surface friendly
transportation of plates or
sheets
Noise-reduction transport
rolls; Noise-reduction
transport roll systems
All in all, our brush transportation rolls offer a number of
advantages for the user through their positive product features:
• Significant noise reduction in transporting sheets > 30%
• Improved and safer working conditions
• Reduced investment costs by applying brush cassettes to
existing shafts
• Reduced wear of the heavy wire brush roll surface
• Roll service life of up to 10 years
• Particularly careful transportation of the sheet surface
• No soiling of the roll surface through the absorption of dirt
into the brush lining
• Reduced maintenance costs for the rolling table
Pain threshold
Obligation of ear protection
Noise level reduction
from 110 dB to 70 dB
with OSBORN transport rolls
120 dB 110 dB 100 dB 90 dB 80 dB 70 dB 60 dB
18

3.1
Brush roll systems
Complete brush roll systems
Through many years of cooperative development work with
machinery manufacturers in the design of rolls and brushing
machines as well as with the operators concerning production
line and process optimization, OSBORN has achieved
wealth of experience in this field. Through our worldwide
sales and service network we are able to guarantee comprehensive
technical support for new production lines around
the globe in all stages of project development from the initial
design to commissioning. A whole list of well-known manufacturers
in the business of strip and heat treatment plants
and rolling mill technology benefits from this expertise, which
ultimately rewards the plant operator in the form of highlyengineered
products, innovative technologies and cost effective
solutions.
Product group
OSBORN product range
Shafts for brush rolls
Brush roll fillings
Re-usable tube bodies
Shafts for back-up rolls and other roll types
Complete brush roll systems
Balancing collars
Bearings and Complete bearing units
Splash rings
Other fittings and accessories
Transport boxes and packaging concepts
In addition to the manufacturing of complete brush rollers
with different shafts and body constructions, our range of
services also includes bearing units, splash rings and accessories.
We also manufacture and supply shafts and complete systems
for other roll types used in strip line systems. These
come without or upon request, with hard chrome,
polyurethane, rubber or other special coatings.
Customized solutions for equipment manufacturers
19

Lateral balancing rings with trapezium grooves and adjustable
balancing weights serve to dynamically balance the shafts
from grades G 1 to G 6.3 in accordance to DIN EN ISO 1940.
With certain material grades it is a good idea to pitch the balancing
nut in order to ensure simple disassembly.
The construction of bodies with hollow shafts suitable for
internal cooling is primarily used in abrasive brushes for
heavy-duty applications. Apart from improved brush cooling
with greater frictional heat when used in corrosive mediums,
they continuously and uniformly rinse the brush in operation
from the inside out by means of the centrifugal force, which
leads to improved brush life.
20

3.2
Brush roll systems
Factory Assembly (FA) brush roll systems
At OSBORN, decades of global expertise is consistently combined
with a local, comprehensive all-round service package
on the customer’s premises. In addition to six centralized
technology centres in Asia, Europe, North America and South
America, other OSBORN service centres and local partners
are located in many other countries to offer a comprehensive
service for your rollers. This allows customers around the
globe to directly benefit from our technology and the comprehensive
range of services on-site.
Product group
OSBORN product range
Brush roll re-filling (SPW/NB)
Integrated maintenance service concepts
Re-trimming and re-balancing of brush rolls
Shafts and journal control and repairing
Factory Assembly (FA)
brush roll systems
((Integrated maintenance
service)
Bearing control and exchange
Shaft improvement/adaptation
Shaft straightening
Stress free annealing of shafts
Replacement of end and balancing collars
Replacement of fittings and accessories
Transport and packaging concepts
Supply of brush roll trimming equipment
An extensive transportation network, partly with companyowned
vehicles, provides a quick and easy collection and
return service for customer rollers.
Apart from the direct re-brushing of customers’ shafts or the
on-site assembly of brush cassettes, our comprehensive
range of services includes all worthwhile and necessary
inspections as well as repair and service work related to our
customer’s needs.
We combine global know-how with local full service
21

Upon receipt by our service centre, each roller immediately
undergoes a professional inspection in accordance to the
agreed upon service contract. The condition as well as the
time and expense involved with the maintenance are documented
with the aid of standardised protocols.
The quiet and low-vibration running of the rollers is important
in order to avoid shatter marks or shading on the strip
surface caused by the brush roller. Before recovering, each
shaft is therefore examined with regard to inbalance and concentricity
deviation, in order to align it straight if necessary
and to rebalance it.
The longer the service life of rollers, the more important it is
to have the proper condition of the bearings to avoid additional
downtime or outages. For this reason, bearing units are
checked and maintained by us. If necessary, the bearing unit
or other accessories are renewed.
Conditioning
Worn bearing seats are welded and precisely re-machined to
the original specification.
Following this, immediate re-brushing or assembly of prefabricated
brush cassettes takes place.
Reworking
22

3.3
Brush roll systems
Customer Assembly (CA) brush roll systems
OSBORN has the right solution for customers who want to
recover and maintain their brushes in-house – roller systems
for self-assembly. Our range of products and services
includes cassettes in fully-automatic internally-welded spiral
constructions, disk constructions as well as constructions
assembled on one-way tube bodies and older structures with
single discs or loose spirals. In order to individually adapt
these to existing shaft constructions, they are additionally
provided with one-way adapters, if required.
As such, we can supply the right cassette for almost every different
shaft that a customer has, unlike any other manufacturer
in the world.
At the same time all of the usual filaments, wires or natural
bristles can be processed and realised according to individual
requirements at different trim lengths and densities - from
light to standard, to extremely dense.
We also provide the right equipment for simple follow-up
shearing of the roller on a lathe.
Product group
OSBORN product range
Cassette brush rolls - spiral type (SPW/IV)
Cassette brush rolls - disk type
Customer Assembly (CA)
brush roll systems
Brush rolls - one-way tube construction (SPW/RK)
Hotani ® Cassette brush rolls
Single brush disks
Loose spiral coils (SPW/LS)
Intelligent and well-engineered roll constructions without
complicated clamping systems make the exchange of brush
coverings fast and simple.
OSBORN brush cassettes are trimmed in sets. Each individual
segment is labelled and marked in accordance with the
assembly instructions. This ensures simple and complete
assembly without diameter variations.
Cassette systems for simple self-assembly onto customers’ shaft
23

With modern shaft constructions from OSBORN it is possible
to avoid balancing the shafts.
Precision manufactured inner diameters in narrow tolerance
ranges ensure that the individual cassettes optimally sit on
the shaft and prevent vibrations when running.
24

3.4
Brush roll systems
OSBORN HDL® brush rolls
OSBORN International once again sets a new benchmark in
brush technology with HDL ® brush rollers - the latest development
from us. By combining streamlined brush construction
with specially developed micro fibre fill materials, we
have been able to introduce a product with significantly
improved performance levels and wear properties. In addition,
the expertise from years of close cooperation with
technology partners and line manufacturers in Japan,
Europe and the United States as well as from the ever
increasing demands on line operators, has been brought
together.
Product group
OSBORN product range
Microfibre/multifilament high-density brush rolls, abrasive or non-abrasive
Individual concepts improved brushing application in process lines (lifetime and brush performance)
OSBORN HDL ® brush rolls
Complete brush roll systems
Factory Assembly (FA) brush roll systems
Customer Assembly (CA) brush roll systems
Adaption/improvement of existing rolls/shafts
OSBORN HDL® - the benchmark in lifetime and brush performance
OSBORN HDL ® provides even more than this. What we mean
by this concept is an optimisation approach to strip lines in
regard to the various brush applications as well as the working
parameters of these rollers.
In the first step to find a solution for you, we will analyze the
current fine weaknesses. Depending on the type of line and
degree to which the brushes are required for cleaning,
degreasing and surface activation, an individual covering is
25
defined for the roller. This covering is made from non-abrasive
and/or abrasive micro fibres and monofilaments. Parallel
to this, the shaft construction is optimised and adjusted. In
general, the customers’ existing shafts can be used. The
usage parameters of the respective brush rollers are evaluated
with regard to cooling, in-feed and revolution speed. We
then draw up a customized optimisation recommendation.

Compared to conventional standard brushes, OSBORN HDL ®
rollers offer decisive advantages:
Micro filaments improve strip cleanliness
• Significantly increased lifetime and reduced operating,
maintenance and overall brush costs
• Improved cleanliness levels in strip cleaning, contributing
to quality improvements, process optimisation and
increases in line speed
• Targeted and better control of the rollers due to the compact
design with higher density make a significant contribution to
reliability and a controlled process
Unlike conventional mono-filaments with bristle diameters
ranging between 0.15 and 1.5 mm, our Novofil micro-fibre
material can also reach rough depths of strip surfaces. This is
due to their very thin thread thicknesses of up to 0.02 mm,
which brings with it significantly improved cleaning and
degreasing levels. In the process, a multi-filament bristle can
be made from several hundred micro fibres.
Due to the extremely high density and the individual mix with
new, especially hard and rigid abrasive materials, heavy soiling
and coarse metallic rolling retentions are removed in a
way which is better than ever before.
26

3.5
Brush roll systems
Lipprite ® abrasive non-woven rolls
Through the merger of the groups OSBORN International and
Lippert-Unipol, we have been able to significantly expand our
range in the field of rollers for achieving any technical or optical
surface finishing.
In the process, Lipprite ® abrasive rollers represent an alternative
to brush rollers in various applications. Besides finishing
applications, they are used for working-roll cleaning, for surface
activation, as well as for de-scaling.
Lipprite ® - the abrasive alternative for a perfect surface
Overview of the roller coverings and material specifications for Lipprite ® abrasive rollers
Aluminium oxide abrasive grain (AI2 O3)
Silicon carbide abrasive (SiC)
A1 extra coarse XCRS Grain 36
A2 coarse CRS Grain 80
A4 medium MED Grain 100
A6 fine FN Grain 180 (240)
A7 very fine VFN Grain 280 (320)
Different hardness specifications for Lipprite ®
103 - soft
105 - medium
107 - hard
109 - very hard
The processing results achieved by Lipprite ® abrasive rollers
may vary depending on the roller specifications, surface and
individual usage parameters. For orientation, the following
approximate values for the achievable surface roughness (Rt)
are:
• A4 (coarse) = 3.3 - 3.9 µm
• A6 (fine) = 2.9 - 3.6 µm
• A7 (very fine) = 1.1 - 1.8 µm
S4 medium MED Grain 100
S6 fine FN Grain 180 (240)
S7 very fine VFN Grain 280 (320)
S8 super fine SFN Grain 500
S9 ultra fine UFN Grain 800
S10 micro fine MFN Grain 1500
Additional Lipprite ® impregnation for increase lifetime and
roller corrosiveness
PH 90
PH 210
Standard hard impregnation
extra hard
Based on many years of experience or by individual tests on
our test lines, we are able to specify the right product in a targeted
way for almost any surface roughness required.
Contact our application engineers.
27

Lipprite ® abrasive rollers are manufactured
from abrasive non-woven
flaps through radial adhesion to a
core. The abrasive grinding grain
made of silicon carbide (SiC) or aluminium
oxide (Al2O3) is, at the same
time, embedded into the surface of
the random web fibre non-woven
material (made of polyamide or other synthetic material) by
means of resin. The corrosiveness of the roller is individually
determined by the density of the material, i.e. the number of
flaps.
An optional additional impregnation makes the roller even
more aggressive and increases the life span. It is necessary to
keep in mind, however, that because of the significantly
increased hardness, impregnated rollers are less flexible. As
such, surface undulations can be harder to balance, which
may result in a less uniform finish or, in terms of the machining
profile, visual shading.
Technical data and product characteristics:
• max. roller width 2000mm
• max. roller diameter 450mm
• Versions available with or without impregnation
• Rollers are dynamically balanced in accordance with DIN
EN ISO 1940
Recommendations concerning the use of rollers:
• Use in wet or dry operations
• Optimum cutting speed 15-25m/s
• Line (strip) speed or feed speed up to 30m/min. (max.)
• Processing in the opposite direction to the running direction
of the material feed
• Optimum depth of immersion 2-6mm, depending on the
roller diameter and hardness
• Oscillation improves the uniformity of the machining profile
28

4
NOVOTEX ®
non-woven rolls
Products and applications
Strip lines and rolling mills are equipped with a large number
of different rolls for completely different tasks and applications.
Through ever-higher line speeds and steadily increasing
demands in terms of quality and process reliability, the
demands made on roll covers and surfaces also increase. As
such, non-woven rollers, with their special material properties,
become increasingly important within the steel, aluminium
and non-ferrous metal industry.
Through close cooperation with one of the world’s leading
manufacturers of technical non-woven materials, OSBORN
has managed to develop a highly-engineered series of products
under the NOVOTEX ® brand name, which are able to fully
satisfy our consumers’ expectations in terms of quality, reliability,
and durability at an excellent price/performance ratio.
NOVOTEX ® - convincing in quality and profitability
Material properties and technical benefits
OSBORN’s NOVOTEX ® rollers are used where other synthetic
roller coatings reach their limits and can no longer ensure
optimum results or stable processes. Compared to rubber or
polyurethane, non-woven material offers crucial advantages:
• The porous structure of non-woven fabric in combination
with a large pore volume makes the material compressible
• It is significantly easier to avoid aquaplaning effects
• Through the applied pressure of the random web on a roller
core, a roll coating results which, with a hardness of up to 95
shore A, exhibits an enormous resistance to being cut as
well as a ‘self-healing’ effect in the event of light cuts
• The capillary or suction effect when discharging the nonwoven
structure provides a significantly lower amount of
residual moisture in squeezing applications
• In contrast to elastic, but hardly compressible rubber or
polyurethane coatings, a significant adhesion effect occurs
in the contact area of the strip surface that is under pressure.
Taking these roll coverings into consideration, this is
something that leads to significantly higher and more constant
coefficients of friction.
1 mm 1 µm
29

• This results in excellent wear characteristics with a much
higher roll lifespan in comparison to rubber or polyurethane
• Due to its pore volume, the roller covering is in the position
to absorb small particles of dirt, oil or grease residue
as well as light roller tinsel
• For a sustained period, the surface itself remains largely
free of contamination or hardened material - an important
criterion for permanent, reliable roll operation without fluctuations
in quality
• In addition, the strip surfaces are particularly conserved
and protected from damage
Economic benefits
The material properties and technical benefits described
bring about a series of economic benefits, which make the
use of non-woven fabric rolls a viable option from a cost/benefit
point of view:
Material compressibility of non woven
• Despite high acquisition costs for the individual rolls, the
longer service life ensures a reduction in operating costs
that significantly outweigh the initial costs.
• Significantly longer lifespans for the rolls reduce downtime
and thus, reduce maintenance costs
Compression
Expansion
• Even with the aid of the non-woven roll, quality and process
improvements gained in manufacturing operations con-
NOVOTEX ® non-woven roll
Conventional rubber roll
Friction coefficient as a feature of the oil film for solvent based liquids
0,30
0,25
Friction coefficient
0,20
0,15
0,10
0,05
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
Area weight of oil film (g/m 2 )
30

Product range
In addition to non-woven fabric coverings, our range of products
includes the production of shafts as well as the recovering
of worn out rolls. We offer complete systems specifically
for the construction of lines including bearing units and shaft
accessories. Users can benefit from our maintenance service
which includes the examination and repair of damaged rolls
as well as accessory parts.
Product group
OSBORN Product range
Non-woven coverings and re-coverings
Shafts for non-woven rolls
Complete rolls incl. shafts and bearing units
Integrated maintenance service concepts
NOVOTEX ®
non-woven rolls
Re-trimming and re-balancing of used rolls
Partial repair of damaged roll coverings
Shaft and journal control and repairing
Bearing control and exchange
Replacement of fittings and accessories
Transport boxes and packaging concepts
31

Materials
When selecting the optimum non-woven fabric for the individual
application you can rely on the various material qualities which
have been continuously improved over the years. These qualities
are indicated by different colours on our physical product.
Through the new development of the NOVOTEX ® 12 covering
material based on polypropylene, we now also cover squeezing
applications in acidic cleaning and/or pickling stations
using non-woven material.
OSBORN NOVOTEX ®
non-woven material range
Material type
Colour
NOVOTEX ® 09 NOVOTEX ® 10 NOVOTEX ® 11 NOVOTEX ® 12
Brown Pink Orange Grey
Technical data
Basic fibre
Range of hardness
max. operating temperature
max. line loading at
~200 m/min. line speed
max. line loading at
>~300 m/min. line speed
Applicable for liquid categories
main applications
PA PA PA PP
90-94 shore A 70-85 shore A 90-95 shore A 70-80 shore A
100°C 100°C 130°C 80°C
50 N/mm 20 N/mm 100 N/mm 15 N/mm
30 N/mm 10 N/mm 80 N/mm 10 N/mm
20 N/mm --- 50 N/mm ---
Application data
oil and emulsions
water
oil and emulsions
water
oil and emulsions
solvents
acids, alkalines
oil and emulsions
squeezing, pinching squeezing squeezing, driving
breaking
squeezing
Camber ground
The roll deflection is of crucial importance for an optimum and
uniform squeezing result over the entire width of the strip. This
is especially the case in weak or undersized shaft constructions.
When the feed force is too high the roll ‘whips’ leading to
excessive residual moisture in the central area, where as too
little feed force causes wet edges on border areas.
For this reason, OSBORN International defines the optimal
feed force for each non-woven roll and, on this basis, works
out the expected roller deflection. The roll crown will be
ground to either convex or concave contours.
Force
Bending X/Y - level
Too low force:
wet edges
Too high force:
wet centre
To specification:
uniform break
32

OSBORN Innovations for cleaning sections in strip processing lines
Alkaline brush
cleaning
Squeezing rolls
Brush
cleaning
Squeezing
rolls
Squeezing
rolls
OSBORN HDL ® NOVOTEX ® OSBORN HDL ® NOVOTEX ® NOVOTEX ®
Load Runners ®
Brush seals
Alkaline spry
cleaning
Electrolytic
cleaning
Water rinsing
Hot Air dryer
Besides NOVOTEX ® non-woven rollers, the OSBORN range
includes more innovative products for cleaning sections in
strip lines, such as HDL ® brush rollers, Load Runners ® and
innovative equipment technology.
Brush seals units, which come in temperature, alkaline or
acid-resistant versions for sealing inlets and outlets in online
components, complete our product range.
Applications
Non-woven rolls can be used in all strip lines or rolling mills
for steel, stainless steel, aluminium and non-ferrous metals.
They include:
• Hot-dip galvanizing lines
• Continuous annealing lines
• Annealing and pickling lines
• Cold rolling mills
• Skin-pass mills
• Colour and/or organic coating systems
• Electrolytic galvanizing lines
• Cleaning or degreasing lines
and a whole range of other types of line. They also significantly
contribute to improving product and process quality.
33

Applications
Pressure rolls
S-rolls / Tension rolls /
Bridle rolls
Squeezing rolls
When used as bridle rolls, tension rolls, steering rolls or
deflector rolls, the advantages of non-woven fabrics over
other synthetic coatings are especially clear. In a dry state and
especially in wet conditions, a non-woven fabric has an excellent
and above all constant friction coefficient both on oil as
well as on watery mediums.
The friction coefficients of rubber or polyurethane-coated
rollers, however, are very low; something which can easily
lead to aquaplaning in the case of non-driven roller, e.g. a
floating of the roller. This can result in strip slippage, which
causes scratches and damage to the surface. On the other
hand, non-woven coatings adhere well to the strip surfaces.
This allows much higher tensile forces to be achieved, and
strips can be held tightly and controlled much more accurately.
Even when applied to braking or tension rolls, the material
properties speak in favour of the non-woven roll. Because of
the strong and stable adhesion between the roll and the strip
surface, strips can be evenly pulled or control-braked even at
high plant speeds.
Deflector rolls
Squeezing rolls ensure lower residual moisture than rubber
or polyurethane coatings. On account of the capillary or suction
effect of the non-woven material, fluid displacement at
the edges is reduced, and the strip edges dry better. In addition,
the special properties of non-woven materials prove
their worth in terms of resistance to cuts and durability.
Transport rolls /
Carrying rolls
Tension rolls /
Brake rolls
As oiling or applicator rollers, non-woven coatings ensure the
uniform application and distribution of liquid coatings
because of their sponge effect. Due to their porosity and pore
volume, they are in the position to absorb liquid and, under
pressure, to dispense it again evenly and/or to distribute it on
the surface.
The special surface protection, which is created by absorbing
small dirt particles into the roller surface, is visible in pressure
rollers made of non-woven material especially for soft and
sensitive surfaces such as aluminium e.g. coil strips in cold
rolling processes. Line speeds of over 1000m / min present
no problems.
Applicator rolls
A similar situation applies to the use of a non-woven roller as
a transporting or carrying roll. The soft and absorbent surface
of the roll prevents scratches or damage, thus ensuring the
smooth transfer of the strip.
34

5.1
Innovative equipment technology
Vacuum squeezing systems
By connecting a pair of squeezing rolls made from special
micro fibre – non-woven material with simple vacuum technology
– we are able to offer an innovative, energy-saving
and environmentally-friendly system for strip drying in a variety
of process lines. Through this technology, which has been
proven and established in Japan for decades, it is sometimes
possible to replace entirely a fan or hot-air dryer. As a result,
a single line can achieve annual energy savings of up to EUR
100.000.
Product group
OSBORN Product range
Complete systems including vacuum pump
Microfibre squeezing rolls
Vacuum squeezing rolls
Complete units including frame construction
Service and repair of used rolls
Supply of equipment for retrimming of used rolls
Bearing control and exchange
Dry surfaces and very low energy consumption without hot air
The function of the system is simple. The vacuum generated on
the perimeter absorbs the liquid remaining on the strip surface
into the roll supported by the capillary action of the micro fibre
non-woven covering. Through the hollow shaft on its perimeter,
which has numerous holes on it, fluid is sent via the vacuum
pump to the existing fluid circuit.
Significant quality and process-related optimisation is created
through the vacuum technology with absolute dry strip edges as
just an example. Displacement through the gap in the squeezing
rollers on the edge area is eliminated entirely by the strong vacuum,
and moreover, the need for subsequent expensive/laborious
drying is completely removed.
35

Microfibre squeezing rolls in combination
with energy saving vacuum technology
The advantages of the vacuum roller especially become more
relevant in comparison to conventional squeezing rollers on
shatter plates or extremely rough strip surfaces.
OSBORN rolls function with a very soft surface and only minimal
contact pressure. As such, the coating is significantly
less prone to wear and essentially more resistant to damage
from strip edges than in the case of traditional squeezing
rolls. Without its own power, the limited in-feed of the roll
preserves the condition of the rolls, as well as the bearing and
the line itself. This creates a lifespan for the rolls averaging
four to five years (depending on individual application) with
only minimal maintenance. All that is needed is trimming
operation and follow-up grinding of the roll surface from time
to time.
As the example below shows a typical strip cleaning line
through the use of NOVOTEX ® non-woven rolls in the third
and fourth exchange of the squeezing roller pair, it would be
possible to dispense with the hot-air drying facility entirely in
favour of a vacuum squeezing system.
Squeezing rolls
Vacuum squeezing system
can replace hot air drying
NOVOTEX ®
Another important advantage is that this system innovation is
extremely simple to implement into existing strip lines. Only
the last pair of squeezing rolls in the plant has to be exchange
out. At the same time, the external dimensions of the rolls
normally remain unchanged and the existing bearings can be
used. Even when additionally installed into an existing strip
line, the space requirement for a complete unit with a frame
construction is less than one metre width. The vacuum unit
itself also requires very little space and does not have to be
placed directly on the pair of rolls.
Water rinsing section
Tell us your specific problem in detail, and we will prepare a
proposal for a complete optimisation concept.
36

5.2
Innovative equipment technology
Brushing equipment for strip processing lines
By linking our technological leadership in brush rollers with
the competence and experience gained from teaming up with
a wide range of line installers across the world, we are, in
cooperation with selected partners, in the position to offer
well-engineered and individually adapted brushing machines
and line concepts, which go further than the established standard
machinery. Our focus primarily lies in replacing old
equipment, which no longer works optimally in existing lines,
while at the same time optimising brush rollers and usage
parameters in order to achieve sustainable quality and
process improvements.
New intelligent concepts for brushing machines
Along with this background, we are also able to offer a new, fully
patented machine package which includes a variety of innovative
developments:
• A rigid machine housing which is heavily cushioned against
vibrations and protected against corrosion made of a composite
stainless steel/mineral cast construction
• Compact and extremely dense OSBORN HDL ® brush rollers enable
precise control of the depth of immersion
• Easy and quicker replacement of the rollers within a few minutes
using an insertion skid with no additional dismantling tools
• Compact design enabling the unit to require little space - only
1500 mm for each upper/lower brush for strip widths up of to approx.
2000 mm
• Easy and precise positioning of the rollers through mechanical
clamping
• Optimum and reliable feeding of the brush rollers via the immersion
depth by means of height adjustment using precision lifting spindle
elements with a servo positioning motor (parallelism tolerance
approx. 0.1 mm)
• Replacement of the rollers without disassembling the bearing units
• Optical control at any time through side access doors with large windows
on the operator side and the interior lighting of the plant
• Non-contact measurement of the roller diameter in operation
• Optional construction according to the brush/brush principle
Brush / Brush
Low vibration
Brush / Back-up-roll
Increased vibration
37

For many years, Japanese lines have maintained a leading
role in technology. In recent years, we have been able to successfully
combine new line projects with renowned steel producers
in Europe, North America, Asia and Africa together
with our Japanese partners by adjusting the components to
international standards.
• With these lines, the brush/brush principle instead of the
conventional brush/back-up roll design provides a number
of advantages.
• Due to the reduction of required roll pairs by half, a 50%
space saving is achieved.
• In the case of thin straps, the brush in the border area no
longer works on the back-up roll but combs in the opposite
brush. Fully uniform wear of the brush balling is achieved in
the border area through the additional oscillation of the
rolls.
• In all, the performance of the respective strip cleaning unit
is significantly improved. As a result, strip quality and line
speed can be increased.
• Acquisition and maintenance costs are correspondingly
reduced.
• Above all, when exchanging brush machines in existing strip
lines, valuable space for additional pre-cleaning sections
can be achieved in addition to more intensive brushing.
• The contact surfaces strip/upper brush and strip/lower brush
are identical. This reduces vibrations. Through gentler running
of the strip, shading and shatter marks on the
strip surface are avoided.
Brushing machine in brush / brush construction including oscillation
38

6
Load Runners ®
Idler rollers and load rails
The name Load Runners ® stands for five decades of experience
in, the manufacturing of idler rolls and guidance systems for precision
moving heavy loads in difficult conditions. Line builders
and operators of rolling mills, strip lines or heat treatment plants
trust in OSBORN’s coil, plate, tray and roller transport or bearing
equipment as well as the company’s automatic doors and a
whole host of applications based on this technology.
Apart from an extensive standard program of over 300 articles
in stock or available at short notice (up to a diameter of
250mm), special sized rolls can also be tailor-made in small
quantities for special requirements.
Load Runners ® carry heavy loads in harsh environments
39

Types
Plain Stud Style
· radial and thrust loads
· easy to install
Plain Eccentric Stud Style
· radial and thrust loads
· easy to install
· vertical adjustment
Plain Yoke Style
· radial and thrust loads
· higher capacity than stud style
Flanged Stud Style
· radial and thrust loads
· easy to install
Flanged Eccentric Stud Style
· radial and thrust loads
· easy to install
· vertical adjustment
Flanged Yoke Style
· radial and thrust loads
· higher capacity than stud style
V-Grooved Stud Style
· radial and thrust loads
· roller profile sheds solid contaminants
V-Grooved Eccentric Stud Style
· radial and thrust loads
· roller profile sheds solid contaminants
· vertical adjustment
V-Grooved Yoke Style
· radial and thrust loads
· higher capacity than stud style
· roller profile sheds solid contaminants
Cam Runner
· composite outer
· stainless steel shaft
· wet environments
U-Grooved Stud Style
· wire guides
· idler pulleys
· easy to install
Flanged Crown Style
· concentric and eccentric
· radial and thrust loads
· use on channels and I-beams
Crown Yoke Style
· radial and thrust loads
· higher capacity than stud style
Shafts for Yoke Style Idler-Rollers
Load Runners ® idler rolls are tightly sealed and greased for
their entire service life. As such they are insensitive to dirt,
moisture and extreme temperatures. Long-life and maintenance-free
operation ensures high levels of economy.
The treads are made of high-strength steel and are then surface
hardened to 55-60 HRC. As such, they feature an especially
wear-resistant surface with a tough core.
The precision tapered roll bearings and grooved ball bearings
used are particularly suitable for both radial and axial loads
and can even be used at high speeds. This secures key advantages
over conventional needle bearings.
Precision adjusted and hardened guiding rails made of highduty
alloy steel are extremely resilient, wear resistant and
free from twist effects. As such, heavy loads can be moved
precisely and reliably.
Our complete Load Runners range
can be found in our catalogue,
“Load Runners ® - Idler-Rollers and
Load Rails for high-capacity load
handling”.
www.loadrunners.de
www.loadrunners.com
www.osborn.de (product area)
40

7
Fill materials
Synthetic monofilaments - NON ABRASIVE
Novofil NN
Novofil NM
Novofil NH
Novofil HR
Novofil TR
Novofil PR
Novofil PT
Material group PA 6 PA 6.6 PA 6.12 PA Special PP PBT
Density (g/cm 3 ) 1,14 1,1 1,07 1,14 1,16 0,9 1,5
Temperature resistance
Permanent (°C) 90 90 90 95 190 70 100
Max. short-term (°C) 120 120 120 120 250 100 130
Water absorption
(at 23°C) 10% 8% 3% 9% 7,50%

Metallic and non ferrous wires
Steel wire
CD Steel wire
AB Steel wire
Brass coated
Steel wire
Cord wire
Stainless
Steel wire
highly noncorrosive
stainless
steel wire
highly heatresistant
stainless
steel wire
Brass wire
Bessemer wire
Phosphor-Bronze
wire
Material group Carbon Steel Steel Steel Steel 1.4301 1.4401 Special Brass Steel Phosphor
steel alloyed alloyed brass coated brass coated 1.4541 1.4571 soft Bronze
Type
crimped crimped crimped crimpedcrimped crimped crimped crimped crimped crimpedcrimped
Density (g/cm 3 ) 7,85 7,85 7,85 7,85 7,85 7,90 8,00 8,00 8,30 7,80 8,90
Temperature resistance
Permanent (°C) 300 300 300 300 300 620 500 1150 170 250 170
Wear properties
Elasticity modul (kN/mm 2 ) 210 210 210 210 210 195 195 195 80 200 110
Tensile strength (N/mm 2 ) 1900 2100 2400 2300 1900 1800 1800 1600 900 700-1200 1000-1300
Hardness (Knopp) 480 500 630 530 530 370 400 160 200 330
Fatique resistance - 0 + + + 0 - + - - 0
Erosion performance - 0 + + + 0 - 0 - - -
Chemical resistance
Against alkalines - - - 0 0 + + + + - +
Against acids - - - - - 0 + + - - 0
Application medium
medium
heavy
heavy medium heavy medium medium medium light light
medium
light
Micro-fibre multifilament
Natural fibres and animal hair
Novofil MY
Novofil MY-A
Novofil MY-S
Novofil MX
Horse hair
Tampico
Material group not abrasive abrasive Filament
abrasive
mixture
Abrasive material - Al2O3 SiC SiC/Al2O3
Properties
Micro-fibre multifilaments ae usually
manufactured with high densities
into special OSBORN HDL ®
brush constructions.
The filament selection and specification
will be defined and customized
to the specific application.
Our application engineers are glad
to give further assistance.
Material group Animal hair Natural fibre
Properties
- very soft bristle
with low static
charging and
excellent sealing
effect
- suitable for careful
cleaning of
extremely sensitive
surfaces, to
apply liquids or
for brush sealings
- very good temperature
resistance
as well as
electric conductivity
- used for dedusting,
light cleaning
and applying
polishing
emulsions
All information without engagement
42

8
Technical information
An optimal brush result is determined by different parameters.
After selecting the appropriate bristle, brush design,
fill density and trim length in the process, we focus on the
correct operational parameters.
Criteria such as surface speed, brush speed, depth of
immersion and contact pressure have to be taken into
account and individually defined under the given framework.
Kissmark in dependence on depth of immersion and brush diameter Ø
120,00
100,00
Kissmark (mm)
80,00
60,00
40,00
20,00
0,00
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50
Depth of immersion (mm)
Ø 250 Ø 300 Ø 330 Ø 350 Ø 400
Recommended surface speed / Rpm for different applications
2500
2000
Rpm (min -1 )
1500
1000
500
0,00
150 200 250 300 350 400
Brush diameter Ø (mm)
Dedusting (10 m/sec) Cleaning (13 M/sec) Work roll cleaning (15 m/sec) Descaling (18 m/sec)
Different applications and fill materials require different
speeds, and the appropriate speed depends on the roll
diameter.
The optimum contact pressure can vary greatly as well and
depends on the brush construction and the fill density. The
decisive factor in achieving the required brush result is the
immersion depth, as a brush tool works primarily with the
bristles and/or the tips of the wire.
The tables in this section provide approximate values and
indications. For detailed information and individual recommendations,
please consult our application engineers who
will be happy to help.
43

Table of surface speeds in metres per sec.
Brush-Ø
(mm)
Surface speed (m/sec.)
Surface speed (v) =
Brush diameter (d) x π x speed (n)
1000 x 60
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
400 477 525 573 621 668 716 764 812 859 907 955 1003 1050 1098 1146 1194
390 490 539 588 637 686 735 784 833 881 930 979 1082 1077 1126 1175 1224
380 503 553 603 653 704 754 804 854 905 955 1005 1055 1106 1156 1206 1256
370 516 568 619 671 723 744 826 878 929 981 1032 1084 1136 1187 1239 1290
360 531 584 637 690 743 796 849 902 955 1008 1061 1114 1167 1220 1273 1326
350 546 600 655 709 764 819 873 928 982 1037 1091 1146 1200 1255 1310 1364
340 562 618 674 730 786 843 899 955 1011 1067 1123 1180 1236 1292 1348 1404
330 579 637 694 752 810 868 926 984 1042 1100 1157 1215 1273 1331 1389 1447
320 597 657 716 776 836 895 955 1015 1074 1134 1194 1253 1313 1373 1432 1492
310 616 678 739 801 863 924 986 1047 1109 1171 1232 1294 1355 1417 1479 1540
300 637 700 764 828 891 955 1019 1082 1146 4210 1273 1337 1401 1464 1528 1592
290 659 724 790 856 922 988 1054 1120 1185 1251 1317 1383 1449 1515 1581 1646
280 682 750 819 887 955 1023 1091 1160 1228 1296 1364 1432 1501 1569 1637 1705
270 707 778 849 920 990 1061 1132 1203 1273 1344 1415 1485 1556 1627 1698 1768
260 735 808 881 955 1028 1102 1175 1249 1322 1396 1469 1543 1616 1689 1763 1836
250 764 840 917 993 1070 1146 1222 1299 1375 1451 1528 1604 1681 1757 1833 1910
240 796 875 955 1035 1114 1194 1273 1353 1432 1512 1592 1671 1751 1830 1910 1989
230 830 913 996 1079 1163 1246 1329 1412 1495 1578 1661 1744 1827 1910 1993 2076
220 868 955 1042 1129 1215 1302 1389 1476 1563 1649 1736 1823 1910 1997 2083 2170
210 909 1000 1091 1182 1273 1394 1455 1546 1637 1728 1819 1910 2001 2092 2183 2274
200 955 1050 1146 1241 1337 1432 1528 1623 1719 1814 1910 2005 2101 2196 2292 2387
190 1005 1106 1206 1307 1407 1508 1608 1709 1809 1910 2010 2111 2211 2312 2412 2513
180 1061 1167 1273 1379 1485 1592 1698 1804 1910 2016 2122 2228 2334 2440 2546 2653
170 1123 1236 1348 1460 1573 1685 1798 1910 2022 2135 2247 2359 2472 2584 2696 2809
160 1194 1313 1432 1552 1671 1790 1910 2029 2149 2268 2387 2507 2626 2745 2865 2984
150 1273 1401 1528 1655 1783 1910 2037 2165 2292 2419 2546 2674 2801 2928 3056 3183
Optimal brush performance is achieved through the use of
compact brushes and high quality fill materials.
Consequently, cooling plays a crucial role, as overheating
can quickly lead to the bristles becoming brittle causing
premature breakage. The brush cooling facility in the plant
/ line is optimised by correcting and adjusting the angle of
spray and flow rate. In turn, this significantly extends the
lifespan of the rollers. The selection of the correct spray jets
also plays an important role.
Terminology
APL:
BAL:
BL:
CAL:
CAPL:
CCL:
CGL:
CL:
CPL:
CRM:
DL:
DPL:
ECL:
EGL:
ETL:
Annealing Pickling Line
Bright Annealing Line
Brushing Line
Continuous Annealing Line
Cold Strip - Annealing Pickling Line
Color Coating Line
Continuous Hot-dip Galvanizing Line
Cleaning Line
Continuous Pickling Line
Cold Rolling Mill
Degreasing Line
Descaling Pickling Line
Electrolytic Cleaning Line
Electrolytic Galvanizing Line
Electrolytic Tinning Line
FL: Finishing Line
GL: Grinding Line
HAPL: Hot Strip - Annealing Pickling Line
HCM: Hot Continuous Mill
HHT: Horizontal Heat Treatment Plant
HRC: Hot Rolled Coils
HFM: Hot Finishing Mill
HRFM: Hot Reversing Finishing Mill
HRM: Hot Reserving Mill
PL: Polishing Line
PLTCM: Pickling Section of Combined Tandem Cold Mill
SL/CCL: Slitting/Cross Cutting Line
SPM: Skin Pass Mill
TLL: Tension Level Line
TM: Temper Mill (Kaltwalzgerüst)
44

9
Our further product range
OSBORN Load Runners ®
Load handling systems for precise movement of heavy loads in demanding
industrial applications.
www.loadrunners.de
OSBORN TOP
High performance power brushes. Superior range for demanding applications
and heavy-duty conditions in industrial settings.
www.top-brush.com
OSBORN Novofil ®
Abrasive nylon brushes in Hi Tec filaments, rectangular and round in
Diamond, Zirconium, Aluminium Oxide and Silicon Carbide. Available in a
wide range of grit values.
OSBORN MultiStrip ®
Saving thermal energy; reducing noise; protecting against insect and vermin
infestation; sealing against dust, dirt, water and smoke; cleaning of
industrial and commercial conveying systems.
www.multistrip.de
Microabrasive brushes and miniatur brushes
Flexible, highly efficient brushing tools for surface finishing of small bores
and cross hole deburring.
45
www.microabrasive-brush.com

Multizack system and punched roller brushes
Products for a wide range of applications: Brushes for cleaning, deburring,
transporting, sorting, washing, guiding and wood structuring.
Brushes for weld cleaning
Power driven brushes for the pipeline industry, e.g. cleaning the internal diameters
of pipe, external cleaning, edge preparation, removal of insulation
coatings, remedial work, cleaning weld seams prior to welding and weld
bead deslag.
www.pipelinebrush.com
OSBORN ATB ®
ATB - Advanced Technology Brush System
Disc brushes with abrasive high-tech filaments. ATB disc brushes have fill
density 4 times higher than other disc brushes manufactured according to
the conventional punched method.
OSBORN Novoflex-B ®
The flexible honing tool!
Lippert-Unipol, Polishing and surface finishing tools
Solutions for any kind of polishing and surface finishing applications:
Abrasive non-woven tools, abrasive brushes in various constructions, coated
abrasive tools, polishing emulsions as well as polishing buffs and mops
made from cloth, Sisal, Sisal/Cord, Sisal cloth and Notiflex non-woven
materials.
www.lippert-unipol.de
46

Brazil • China • Denmark • France • Germany • Great Britain • India • Mexico • Portugal • Romania • Spain • Sweden • USA
OSBORN International GmbH · Manufacturer of Industrial Brushes, Surface Finishing Tools and Load Runners
Ringstraße 10 · 35099 Burgwald-Germany · Phone: +49 (0) 64 51 / 5 88-0 · Fax: +49 (0) 64 51 / 5 88-208
eMail: techsales@osborn.de · www.osborn.de · www.metallurgy-brush.com
Subject to alterations. 2033 GB 07/09
ISO 9001-2000 Certified Quality System
Members of Jason Finishing Group