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Web processing applications like corrugators, paper sheeters and other converting machines need to unwind the material for subsequent operations maintaining the web tension constant in time. Every roll stand requires a braking system and every plant has more than one roll stand.

Standard industrial brakes are usually made of a lead based alloy. Their chemical composition can be a hazard to plant workers, especially when the brake pads start to wear off.

Particulate Matter (PM), or particle pollution, is a mixture of solid particles and liquid droplets found in the air. Some particles, such as dirt or smoke are large enough to be seen in the air, others are so small they can only be detected using an electron microscope. These particles are released in the environment from different sources and have attracted increasing attention in recent years for the environmental and health issues they can cause.

There is a potential impact of the emitted PM on the human health, depending on the mechanisms of formation and toxicity of the particles. Particulate matters generated by brake wear are affecting environment and human health in two ways, associated to their size and air concentration, but even to their chemical composition

In the tissue paper production and transformation plants, for example, the use of the bridge crane is also used, but as for the forklift, it cannot reach and cover the entire area of ​​the factory.

Inhaled PM are deposited in the nose and throat, causing irritations, while fine and ultrafine particles may penetrate deep into the lungs, causing inflammation, create free radicals in the body cells and produce damage to DNA, especially for oxidation reactions and related biological stress. Several studies proved that the nano-sized particles may become blood-borne and be transported to other target tissues and organs and become carcinogenic agents.

Since specific epidemiological studies indicated a link between airborne PM and adverse health effects experienced by plant workers, it is important to reduce emissions of pollutants at the source.

Health and environmental impacts of PM from brakes are regarded as important criteria for the selection and development of better performing materials and for the design of more effective brake systems.

Pad wear depends mainly on three factors:

• specific pressure
• peripheral velocity of the discs
• operating temperatures

Working conditions in plants are extreme and working temperatures need to be drastically dissipated.

Sometimes, in fact, brake components overheating can cause a loss of tension consistency and contributes to a consistent increase of the pad wear and powder pollution.

Latest generation monodisc brakes have a maximum heat dissipation of 6kW. Turborex works at lowest temperatures thanks to a multidisc system and a double fan ventilation, reaching the result of a maximum heat dissipation of 12 kW thus avoiding brake components overheating.

The thermal power and pressure is distributed on multiple surfaces, providing continuous cooling airstream across pads and discs, thus preventing loss of tension consistency and reducing the pad wear and powder pollution.

RoHS (Restriction of Hazardous Substances), also known as Directive 2002/95/EC, originated in the European Union and restricts the use of specific hazardous materials found in electrical and electronic products. It restricts materials that are hazardous to the environment and are dangerous in terms of occupational exposure during manufacturing and recycling.

Turborex pads are RoHS compliant: 100% asbestos, hexavalent chromium, mercury, cadmium, antimony, lead FREE.

Standard monodisc brakes guarantee between 8500 and 27000 working hours: they need frequent maintenance and spare parts.

Turborex design reduces operating temperatures and peripheral velocity of the discs, ensuring a longer pad life and the lowest dust pollution in the working area and on final product. Moreover, the reduced disc diameter of 180mm means 30% less sliding speed of the friction materials against the disc for a massive reduction of the pad wear and dust emission.

It can guarantee up to 42000 working hours (5 years) with no maintenance on pads and discs, data collected on real field experience, thus reducing costs and procedures.

With the external wear indicator, moreover, the operator can easily see pad wear without having to open the brake.

Turborex is the result of continuous research and improvements based on consolidated experience and collaboration with machine builders and end users.

It is high versatile on any roll stand and has an international patent for the technology applied.

Turborex, pioneer of eco-friendly brakes, has taken the challenge to further reduce operating temperatures and pad wear in the future.