Production-representative densification at pilot scale
A pilot calender verifies what a lab machine cannot: that your densification recipe holds up at production forces. IMC pilot calenders run 300 mm+ web widths at line loads up to 136 metric tons — production-relevant compression on production-representative roll geometry — with induction or oil-heated rolls, closed-loop gap control, and a recipe-driven HMI.
This is the tier where scale-up work gets done. Density-porosity targets validated here transfer to IMC production calenders (up to 418 metric tons, 1 µm closed-loop gap, ±1°C roll uniformity) without re-derivation, because the gap control, force delivery, and thermal architecture are the same design language.
Specifications
| Max line load | Up to 136 metric tons (150 US tons) |
| Roll size | 400–500 mm dia., precision ground to ±1 µm |
| Roll surface | Chrome or tungsten carbide |
| Web width | 300 mm+, configured to spec (to 500 mm) |
| Roll heating | Induction or circulated hot oil, to 200°C+, ±1°C across the face |
| Gap control | Motorized, closed-loop with thickness feedback; servo-hydraulic live gap control available |
| Line speed | Up to 30 m/min |
| Operating modes | Gap or pressure calendering, no changeover; patch/intermittent-coated electrode support |
| Environment | Cleanroom and dry-room compatible; 24/7 duty |
Specifications shown are representative platform capabilities; each machine is configured to the application.
Available options
Calender/Slitter combination — densify and slit in one machine
Add a cartridge-style slitting section and the pilot calender becomes a calender/slitter line: coated electrode goes in, calendered and slit-to-width rolls come out — one web path, one tension system, one HMI. For teams that need both capabilities, the combination eliminates a second machine purchase, a winding/handling step between processes, and the floor space to match.
Slitting section: 3–7 knife cartridge heads, trim handling, and differential rewind — the same architecture as our standalone slitting lines.
Standard options
What a pilot calender is for
Electrode scale-up — validate anode and cathode densification at real forces before production commitment. Pre-production output — calendered electrode for pilot cell builds and customer qualification. Warm calendering studies — evaluate heated-roll densification across chemistries. Material programs — PTFE, filtration media, and specialty webs at production-representative compression.
From pilot to production
Pilot recipes carry directly onto IMC production calender lines — standalone, or integrated into multi-process systems with laminating, slitting, and inspection inline — with one engineering team across both builds.