Calender line

Calender Line Market Dynamics: Growth and Trends

Market Overview: The calender line market has been gaining traction within the broader machinery sector, reflecting a growing demand for high-efficiency manufacturing processes. According to 360iResearch™, the market for related machinery segments, such as the HVAC Linesets Market, expanded from USD 8.41 billion in 2023 to USD 9.22 billion in 2024, with a robust CAGR of 9.97%, projected to reach USD 16.37 billion by 2030. This trend is indicative of a broader industrial movement towards automation and advanced manufacturing techniques, which are essential for optimizing production lines, including calendering processes. The increasing adoption of innovative technologies and the push for sustainable practices are pivotal in driving growth in this sector.

Industry Insights: Key players in the calender line market are responding to evolving consumer behavior, which increasingly favors sustainable and efficient manufacturing solutions. As industries prioritize eco-friendly production methods, the demand for advanced calender lines that utilize less energy and produce minimal waste is on the rise. Furthermore, the market dynamics are influenced by shifts in distribution channels, with a growing emphasis on e-commerce platforms such as Alibaba.com for procurement. This shift allows manufacturers to reach a wider audience while addressing customer pain points, such as the need for timely delivery and customization options. As the market continues to develop through 2025 and beyond, the integration of smart technologies and sustainable practices will likely remain at the forefront of industry strategies.

Types of Calender Lines

The calender line is an essential machine in the rubber and plastic industry, mainly used to press, shape, and thin the material. According to the configuration of roller numbers and shapes, calendaring machines can be divided into the following types.

• Three-Roll Calender Line

  The three-roll calender line usually consists of a top roll, a middle roll, and a bottom roll. Generally, the top roll and the bottom roll are horizontal, and the middle roll is vertical, which forms a… shape. The three-roll calender line is often used for the production of thin sheets. Compared with other calender lines, the three-roll calender line consumes less energy, which leads to a lower operating cost.

• Five-Roll Calender Line

  The five-roll calender line includes two flat rolls and three support rolls. The three support rolls are distributed between the two flat rolls in a staggered manner. The top support roll and the bottom support roll are horizontal, while the middle one is vertical. The five-roll calender line has a wider swath of material possible compared to the three- and four-roll designs due to an increased processing area.

• Seven-Roll Calender Line

  The seven-roll calender machine consists of two horizontal rolls and five vertical support rolls in a staggered arrangement. The staggered configuration allows the material to be stretched and uniformly heated. The calendering process involves passing the material between the rolls, which exerts pressure to thin and elongate the material into sheets.

  Overall, the seven-roll calender machine is ideal for processing large quantities of raw materials into thinner sheets at a faster rate.

• Multi-Roll Calender Line

  The multi-roll calender machine usually consists of many smaller rolls in a frame. It can be used to produce sheets for various applications, such as flooring, automotive parts, industrial products, and more.

  With appropriate materials, technology, and a customizable number of smaller rolls, the machine can achieve different thicknesses, widths, and specifications to meet particular requirements.

• Special Calender Lines

  There are some other kinds of calender lines, such as embossing calender lines, printing calender lines, chrome calender lines, and polymer calender lines. The embossing calender line is equipped with an embossing roll. It can produce sheets with regular patterns. The printing calender line is equipped with a printing device. It can print patterns on the sheets according to the customers' demands. The chrome calender line is made up of a chrome roll and a rubber roll. The chrome roll is used for heating, and the rubber roll is for cooling. The combination of the two kinds of rolls can strengthen the mechanical properties and the chemical stability of the sheets. The polymer calender line is made up of polymer rolls with various specifications. It can produce sheets with special material and features.

Maintenance and specifications of a calender line

Some calender lines are huge machines, but with proper care, simple repairs and occasional component changes are usually all that is needed to keep them running smoothly. This not only reduces downtime but also saves money and prolongs the life of the machine.

Keeping a calender line machine running smoothly is a requirement for any factory that wishes to maximise output and limit wastage. It is important to note, however, that some tasks must be carried out by professionally trained technicians. These usually include any tasks that require dismantling the machines, such as changing or removing the following parts:

• Drives: The Drives are usually the motors that provide power to roll the cylinders. They can be direct drives, gear drives, or belt drives, depending on the model of the machine. Some machines may have multiple drives on one cylinder or one drive for a single cylinder.
• Roller cylinders: These can be made out of various materials and coatings to achieve the perfect dough for the finished product. Maintenance typically involves ensuring that the surface is clean, and sanitised, with appropriate temperature control and moisture levels.
• Filters: Calender lines have air filters that ensure only clean air comes into the machine, preventing pollution and ensuring a smooth product.
• Electrical panel and motor plan: Usually, electrical panels are safe, but they require a specialist to inspect once in a while. This included ensuring that all wires were connected firmly and securely and that there was no corrosion on the panel. The same goes for the motor plan where the machines having the motors are located.
• Hydraulic hoses and pumps: The hydraulic hoses that transport oil/petroleum products require special inspections by trained technicians. Any cracks or kinks must be addressed immediately to prevent leakage and avoid hazardous situations.
• Vaccine pump: This must be inspected and serviced by professionals who would ensure that there is no leakage and that all oil is pumped into the required areas of the machine in a timely and effective manner.

Some tasks can be performed by line operators, such as keeping the machine clean and sanitised, removing any dust or debris, and ensuring that no foreign objects enter the machine. The sanitisation part is especially important because roller cylinders can sometimes get mould due to moisture exposure. Clearly, if the calender line has air filters, clean air will pass through the machine, but routine cleaning becomes crucial to prevent mould growing on the surface of the product. Some floors may be used for food, which requires utmost attention to hygiene.

An unsanitised machine can cause a lot of wastage when manufacturing products, as even the best chemicals and ingredients will not be able to produce a quality product if the machinery is dirty and unkempt.

Wiping down all surfaces with the required chemical and ensuring the roller cylinders are clean is part of daily maintenance routines performed by factory workers and operators. Production manuals will specify which chemicals can be used to clean, and employees will be trained to ensure they are not used on surfaces not intended to be cleaned with these chemicals.

In some facilities, the machine is sprayed with disinfectants in the form of fog, which is a more efficient way to clean and sanitise far-off areas in the machine. However, this requires the machine to be turned off while the spray is used, as it cannot be sprayed while the calender line is operational.

Usage scenarios of calender lines

Calender lines are primarily used in industries that work with rubber and plastic, such as the automobile and construction industries. In the automobile industry, calender lines are used to produce parts like tires, inner linings, belts, sealing strips, vibration dampers, and others. The inner and outer layers of automobile tires are made using fabric or wire plies in a calendering machine. The calendering machine rolls out a rubber sheet for the ply to be embedded into, forming the basis of the tire.

The vibration-dampening parts in automobiles, such as mud flaps, are also made using calendering machines. Mud flaps are usually made from a mix of rubber and plastic, and the calendering machine is used to form the sheets, which are cut into the required shapes after drying and solidifying.

In the construction industry, plastic calendering lines are used to produce sheets and other parts used for waterproofing and insulating buildings. Calendering machines produce PVC membranes that are used for waterproofing and insulating building sheets.

Other industries that use calender lines for plastic or rubber include the electronic industry, the solar energy industry, and the flooring and film-making industries. Solar energy panels use rubber or silicone sheets that have been produced using a calendering machine. The electronic industry uses calendering machines to produce insulating materials, while the flooring industry uses them to make sheets for different kinds of flooring.

How to choose calendaring lines

A machine's production capacity is critical to its profitability. A high-capacity calender line can process a lot of material in a short amount of time, but that generally also comes with a higher cost and potential maintenance needs. If the capacity exceeds demand, it could be an unwise investment.

The ability to customize a calendering line's features to fit specific needs is essential for many businesses. Options may include different types of rolls, special heating and cooling systems, the ability to process various materials, and more.

Understanding the energy consumption of a calendering line can help business buyers make informed choices. A line that uses less energy could reduce production costs over time even if the upfront cost is slightly higher. Heating methods also vary from electric to steam to gas and selecting the most appropriate one can depend on other existing facilities such as boilers or the local energy grid.

Safety features such as emergency stop buttons, guards, and roll gap controls are important to consider when selecting a calendering line. A machine may have many safety features, but they can only be effective if operators are trained to understand how they work. Manufacturer training and safety manuals are essential when deciding on a Calendering line. Proper training can ensure that operators know how to use the machine safely and properly, reducing the risk of accidents. When provided with adequate training, buyers may opt to select a machine with advanced technologies and a higher cost.

The warranty and after-sale services provided by a machine manufacturer's supplier is an important consideration when buying industrial machinery like a calendering line. A strong warranty and dependable after-sale service can protect the investment and provide peace of mind.

Calender line Q and A

Q1. How has the calendering line machine changed in recent years?

A1. The calendering machine has changed technologically in the control system, automation level, efficiency, and energy conservation.

Q2. Who are the main users of the calendering line machine?

A2. The main users of the calendering machine include rubber manufacturing plants, plastic products factories, and composite material production enterprises.

Q3. What is the market trend of the calendering line machine?

A3. The market trend of the calendering machine may grow steadily in the fields of rubber and plastic. The demand for automation and energy conservation will be durable.

Q4. What is the share of the calendering line machine in the global market?

A4. The share of the calendering machine in the global market is small, but the overall value is considerable because the price of the calendering machine is relatively high.

Q5. What is the growth forecast for the calendering line machine?

A5. The growth forecast of the calendering machine line may continue to grow along with the development of relevant industries such as rubber, plastic, and composite materials.