Rubber & PVC Calendering

Measurement and Control Solutions


FACTS offers a complete set of solutions for calendaring operations including:

    • Calender Gauge Control – Measure & Control the Product
    • Calender Line Control & Drive Systems
    • Bubble Piercer (Blister Breaker) Systems
calendering gauges

ON CAL and AE Gauge

  • Automatic Electric Mill Knife Systems
  • Automatic Trim Knife Systems
  • Width Measurement Systems
  • Screw & Hydraulic Actuator Upgrades
  • Hydraulic Servo Systems & Upgrades
  • Steel Cord Spacing Measurement
  • Centering & Guiding Systems
  • Calender Process Consultation & Training
  • Production & Downtime Report Generation
  • Ticket Printing

Download the Total Calender Solutions Brochure.


Total Calender Gauge Control System


The FACTS Total Calender Control system will generate rapid payback and long-term cost savings by quickly getting your calendered web on spec and reducing variations by 20 – 30%. A reduced standard deviation allows the running product targets to be automatically shifted closer to the minimum boundary without violating specification.

FACTS Gauge Control systems are applicable for all calendaring operations and readily control:

  • Roll Gap Actuators – Screw, Hydraulic or Hydraulic Servo
  • Roll Bending Systems
  • Cross Axis Systems
  • Calender Roll Temperature
  • Cushion

A variety of measurement technologies are available to meet the demands of various calender processes. The FACTS On-Cal 3 Gauge is an industry leader and mainstay technology. The On-Cal 3 is a non-nuclear, precision contact gauge mounted close to the calender nip resulting in low transport delays and fast control response. The On-Cal 3 gauge is also applicable for overall thickness measurements post calender. For those applications requiring an overall scanning profile measurement, FACTS offers:

  • The SME Thickness Gauge
  • The LTM Thickness Gauge
  • Nuclear Beta Gauge
  • X-Ray Gauge


  • Total Gauge Control System (TCC 1600 – for larger scale operations) – Download
  • Total Gauge Control System (TCC 150 – for smaller scale operations) – Download
  • Thickness Monitoring System – Download
  • On-Cal 3 Contact Gauge – Download
  • AE Non-Contact Gauge – Download
  • SME Gauge for Calendered Web – Download
  • LTM Gauge for Calendered Web – Download
  • Profile Scanner for Calendered Web – Download
  • Real World Savings – Download our Case Study
  • Dynamic Target Optimization – Download
  • Calender Gauge Control Tips – Download

Calender Line Control & Drive Systems

calender line controlA complete solution for the entire calendering line including:

  • Control and coordination of all line speeds
  • Tension control
  • Temperature control
  • Let-off splice sequence control
  • Wind-up change over sequence control
  • Hydraulic system monitoring and interlocks
  • Lube system monitoring and interlocks
  • Risk assessments
  • Safety system design and implementation
  • AC & DC drive systems
  • Electrical power panel assemblies
  • Seamless integration with the FACTS Gauge Control system

Bubble Piercer (Blister Breaker) Systems

The FACTS Blister Breaker is a compact, low profile, traversing knife system designed to fit into tight spaces along with the FACTS On-Cal Gauges.

  • The blade holder casters resulting in minimal gum distortion
  • The traverse speed is synchronized to the calender speed
  • Includes 6” User Interface Touch Panel
  • Operates stand alone or integrated with the FACTS Gauge Control system

Automatic Electric Mill Knife Systems

mill knifeThe FACTS Mill Knife System is a rugged twin knife positioning system that will automatically adjust the width of the feed strip based upon the speed of the calender.

  • Knife holder accommodates industry standard knifes
  • Slug increase/decrease function to rapidly impact bank
  • Includes 6” User Interface Touch Panel

Automatic Servo Trim Knife Systems

The FACTS Trim Knife System will track the edge of the web and automatically position the trim knives to maintain a consistent salvage edge. Multiple configurations are available. Please contact us directly to discuss your specific application.

Screw & Hydraulic Actuator Upgrades

  • Replace fixed speed motors with invertor duty motors and drives. Eliminates friction brakes and results in more consistent operation.
  • Replace screw actuator control with hydraulic gauging cylinders. Both long stroke and short stroke options available.

Hydraulic Servo Systems & Upgrades

  • Replace obsolete servo controllers with state of the art
  • Valves and manifold assemblies
  • Complete hydraulic power packages

Steel Cord Spacing Measurement System

wire-spacingThe FACTS Cord Spacing Measurement svystem provides complete cord spacing measurement.

  • Detects bunched, crossed and missing cords
  • Measures cord spacing
  • Confirms cord count
  • Optional marking system for defect location

Calender Process Training

Tim Fisher is one of the foremost calender process experts and can provided consultation and training services tailored to meet your needs. Session topics have included:

  • A consolidated overview to help operation and production personnel better understand the impact of their activities.
  • An in-depth review targeted for engineering and process personnel
  • On-demand process & equipment troubleshooting including the use of measurement, control and data collection tools to assist with root cause determination.