Hot Embossing Calender

The Hot Embossing Calender delivers exceptional throughput with operational speeds of up to 600 meters per minute. This high-speed capacity ensures that even the most demanding production schedules are met without compromising surface quality or design integrity.

Its advanced drive systems allow individual control of each roll, enabling fine-tuned calibration for speed synchronization, tension management, and consistent embossing performance—critical for premium films used in hygiene, packaging, and automotive applications.

Supporting film widths ranging from 500 mm to 3,500 mm, the Hot Embossing Calender is designed for manufacturers who need maximum versatility across multiple product lines.

Whether you’re working with specialty films in narrow formats or producing large-format decorative or technical films, the system adapts seamlessly to varying web widths. Its modular framework and scalable roll design provide the flexibility to shift between formats with minimal mechanical adjustments, helping operators reduce downtime while increasing output capacity and operational flexibility.

Temperature consistency is critical in achieving high-quality, repeatable embossing results. This system features a precision-controlled temperature range of 20°C to 180°C, making it compatible with a broad range of thermoplastic substrates, including PE, PP, PVC, and TPO.

A combination of thermal oil-heated pre-rolls, infrared radiators with adjustable intensity, and double-shell rollers with internal spirals ensures optimized and uniform heat distribution. This allows for effective surface activation and controlled material deformation – enabling both intricate optical designs and haptic textures with superior fidelity.

To deliver flawless surface structures under high-speed production, the Hot Embossing Calender features adjustable line loads up to 120 N/mm. This precise pressure application ensures consistent contact between the embossing and back-up rolls, even under demanding throughput rates. A hydraulic nip control system provides repeatable pressure settings for various material types and embossing depths, eliminating variations and enhancing pattern clarity.

The result is uniform, high-resolution embossing across the entire web width – ideal for producing functional surfaces with visual and tactile effects that meet the highest industry standards.

Designed with application diversity in mind, this calender system meets the unique demands of decorative films, hygiene and personal care films, flexible packaging, and technical films used in sectors such as automotive, construction, and consumer goods.

Its ability to handle multiple substrate types and surface effects — whether matte, glossy, micro-structured, or soft-touch — makes it a go-to solution for manufacturers seeking to enhance product aesthetics and functionality.

Featuring double-shell construction with internal spiral channels, the pre-heat rollers ensure even and efficient thermal transfer across the film surface. This allows substrates to reach the ideal temperature profile before embossing begins—crucial for dimensional stability and design precision.

A dedicated thermal oil circuit precisely heats the pre-rolls, delivering steady and controlled heat without thermal fluctuation. This ensures that even temperature-sensitive films are processed safely and accurately.

Integrated infrared heating elements provide supplemental, responsive heating with adjustable intensity—ideal for fine-tuning surface activation depending on the film type and embossing depth required.

The centerpiece of the system, the laser-engraved embossing roll, features a double-shell design with spiral internal channels. This enables consistent heat distribution throughout the roll, ensuring sharp, repeatable embossing patterns and high surface definition.

A high-performance hydraulic power pack opens and closes the roller nip with exceptional accuracy. This ensures consistent nip pressure during operation and easy adjustments or maintenance during changeovers.

The rubber-coated back-up roller is engineered with a heat- and pressure-resistant surface, maintaining contact integrity and alignment under high-speed, high-pressure conditions—critical for quality consistency.

A contact cooling roll rapidly stabilizes the back-up roll temperature post-embossing. Additionally, double-shell cooling rolls with spiral channels and a dedicated water cooling unit ensure both the embossing and cooling zones remain within optimal operating temperatures, preventing warping and preserving film properties.