We have unsurpassed expertise in themanufacture of super-mirror-polished steel
belts with a choice of IPCO steel grades, belt
widths/thicknesses and polished surface finishes
to meet your specific application needs.
Ipco.com--------super-------------mirror---polished
STEEL---BELTS---------------FOR---FILM/SHEET----------PRODUCTION--------

-----Strong, smoothand flat – the perfectsurface for a polishedperformance
Steel belts are among the most versatile tools available toindustry, being used for everything from chemical processing
to the manufacture of wood-based panels. They’re chosen for
their inherent qualities of strength, durability and the ability
to be used in the most aggressive of environments.

But there’s much more to steel belts thansheer strength: they’re also extremely flat andsmooth, and this makes them ideally suited
to casting applications, where the quality ofend product literally mirrors the quality of thematerial on which it’s produced.
Super-mirror-polished steel belts have beenused in the manufacture of photographic films
and ceramic sheets for many years. Today,
growing recognition of the qualities of thisunique processing material has seen film casting
applications expand to include specialist films
for liquid crystal displays (LCDs) on cameras andnotebooks; thin films for printed circuit boards(PCBs); filter membranes for medical use andplastic films for high quality packaging.

From specialist films for
LCD displays through PCB
films, filter membranes
and plastic films for
packaging, the potential
applications for film/sheet
materials continue to grow2Steel belts can also be used in the productionof multi-layer laminates, and double-beltsystems can apply pressure and heat as well as
providing a perfectly smooth surface.
In other words, wherever there’s a need to
produce high-quality, ultra-flat film or sheet
materials, there’s a potential application for an
IPCO super-mirror-polished steel belt.

Wherever there’s a need toproduce high-quality, ultra-flat
film or sheet materials, there’s apotential application for an IPCO
super-mirror-polished steel belt.

3

Steel belts and IPCO experience
The properties of the steel belt are unique: no other material offers
the same combination of strength, flatness, ease of cleaning,
resistance to corrosion, hardness, flexibility and repairability.
exceptionally high-quality surface. It is produced
via one of two processes – Electro Slag
Remelting (ESR) or Vacuum Arc Remelting (VAR)– and, as the table below shows, is available in
IPCO 1000SA and 1200SA grades.
For applications where the highest surface
specifications are not critical, belts can be
manufactured via the AOD (Argon Oxygen
Decarburization) melting practice.

And when it comes to steel belts, our experienceis without equal. From the development of
the world’s first steel belt, to many otherworld firsts since, our leadership in this field is
acknowledged the world over. And this means
we are able to offer precisely the right grade ofbelt for every application.
The right belt material for your application
Our super-mirror-polished belts are producedby polishing an IPCO stainless steel belt, but
polishing alone cannot produce the optimum
surface quality: the highest surface grades
require special materials.
For this, we use ESR/VAR, a steel with very low
inclusion levels and capable of delivering anA choice of belt thicknesses and widths
IPCO steel belts can be manufactured in a rangeof thicknesses to suit different applications and,as with belt grades and materials, our expertise
ensures that your belt delivers precisely the rightcharacteristics for your application.
Recent years have seen growth in demand
for wider belts and we are now able to meetrequirements for widths up to 3 m.
Belts up to 2 m wide are produced in a single
strip. Where requirements exceed this, twobelts are welded together longitudinally andthe entire surface is ground to ensure even belt
thickness. The whole steel belt surface is thenpolished to deliver consistent quality.
If you have a special requirement – perhaps abelt size that’s not shown here – contact yourIPCO sales office and we’ll provide all the advice
you need.

Belt thicknesses and widths
TypeSteel belt gradeStandardthickness(mm)Typical products / applications

AusteniticAOD

IPCO 1000SA AOD(AISI 316)

1.0. 1.2• Ceramic sheet for fuels cells & capacitors• Filter membrane for medical filters

AusteniticAOD

IPCO 1200SA AOD(ASI 301)

0.6, 0.8, 1.0,1.2, 1.6, 2.0• Ceramic sheet for fuels cells & capacitors• Filter membrane for medical filters

Austenitic
ESR/VAR

IPCO 1000SA ESR/VAR(AISI 316)

1.1, 1.6• Optical film (e.g. TAC, PC, PVA etc.) for LCD panels• Film for substrate use (e.g. PI etc.) for digital cameras,
mobile phones, laptops, solar batteries etc.

Austenitic
ESR/VAR

IPCO 1200SA ESR/VAR(AISI 301)

1.1

• Optical film (e.g. TAC, PC, PVA etc.) for LCD panels• Film for substrate use (e.g. PI etc.) for digital cameras,
mobile phones, laptops, solar batteries etc.

Martensitic
AOD

IPCO 1050SM AOD

0.8, 1.0, 1.2• Extruded packaging film (e.g. PP, PVC etc.) for commodity
goods• Pressed laminate sheet products for PCBs, automotiveparts, fuel cell parts, solar battery parts etc.

Martensitic
AOD

IPCO 1650SM AOD

0.8, 1.0, 1.2,1.6, 1.8, 2.0• Extruded packaging film (e.g. PP, PVC etc.) for commodity
goods• Pressed laminate sheet products for PCBs, automotiveparts, fuel cell parts, solar battery parts etc.

4Smooth, smoother, smoothest –selecting the right polishing grade
The grade of polish applied to your steel belt determines thesmoothness of your end product so it is essential to get this right.

The first two grades in the table below are‘Fine grind’ (FG) and ‘Buff’ (BF). Both use
regular AOD materials and are polished bygrinding or buffing. Thickness variation willbe ≤80µm and the acceptable level of surface
roughness will be agreed with you at the timeof placing the order. Surface conditions canvary depending on the technique used so,
if requested, we will provide a sample. Thisquality is suitable for products such as theceramic sheets used in fuel cells.

The next two grades, PF-0 and PF-1, also use
AOD material but are produced to higher
tolerances with limited inclusions, a smoothersurface and minimal variation in thickness.
Finally, there are the highest grade polishedsurfaces, all of which use ESR/VAR material andare suitable for casting products such as opticalfilms for LCD displays and substrate films forhigh quality electrical products such as digital
cameras, mobile phones and notebook PCs.
We can provide any advice you need on thesuitability of a polished grade to your particularapplication.
Custom solutions mean you don’t need tocompromise
Our experience in this field means we canalso achieve surface grades specific to a yourrequirements, such as a level of inclusions that
falls between our standard grades.
Looking beyond polishing, we can work withyou to develop a solution to any requirement,such as a surface that delivers enhanced filmrelease properties, a unique surface pattern ormaybe even a solution involving us working withsamples of your material to develop a specialsurface.

Polished steel belt surface specifications
Polishing grade

Inclusions

Surface roughness

Thickness variation – typical

Melting practiceFG-0.XXNo definition

Can be specified in range of
Ra = 0.10-0.22 µm≤80 µmAOD

BF-0.XXNo definition

Can be specified in range of
Ra = 0.04-0.12 µm≤80 µmAODPF-0>500 µm≤500 µm

Not allowedNo restriction

Ra ≤0.02 µm(Rz ≤0.08 µm)≤50 µm(except cross welding zone)

AOD

PF-1>500 µm≥100 µm - ≤500 µm<100 µm

Not allowed
Max 20/m2
No restriction

Ra ≤0.02 µm(Rz ≤0.08 µm)≤50 µm(except cross welding zone)

AOD

PF-2>100 µm≥50 µm - ≤100 µm<50 µmNot allowed
Max 5/m2
No restriction

Ra ≤0.01 µm(Rz ≤0.04 µm)≤50 µmESR/VARPF-3>70 µm≥40 µm - ≤70 µm<40 µmNot allowed
Max 5/m2
No restriction

Ra ≤0.01 µm(Rz ≤0.04 µm)≤40 µmESR/VAR5

Getting it right with quality controlat every stage
After polishing, the steel belt undergoes a series of inspection
processes. Data such as thickness, inclusions and surface
roughness is measured, checked for compliance with your agreed
specification and an inspection report produced.
In the case of high-grade polished belts, surface
polish requirements will vary from one customer
to another. For instance, the pore pits createdby minute inclusions may be unacceptable dueto their impact on the quality of end products,
or you may have specific requirements in termsof the shape of inclusions or a small detail in asurface pattern.
For this reason, surface specifications should beclearly agreed at the ordering stage.
In order to avoid problems after delivery, westrongly encourage a factory visit accompanied
by an IPCO specialist. Ahead of your visit, we will

supply full inspection data. For the visit itself,
we will provide whatever support you needto undertake the inspection and, if an issue isidentified, we can discuss modifications.

Support roller
Ensuring smooth
movement of the belt

A factory inspection also provides theopportunity to discuss installation andmaintenance, and we will be happy to answer
any questions regarding cleaning methods andtroubleshooting.
After inspection, the steel belt is packed withprotective films on the surface and delivered toyour location.
Installation and welding of a polished steel belt
In most cases, your polished steel belt can bedelivered in either endless loop form or as anopen length for on-site welding. Either way, theweld quality is critical: the surface has to be thesame across the welding line as it is across therest of its length.
If your belt is delivered in endless form, it will becross-welded and polished in the IPCO factory,
and delivered to your location with a protective
film that should not be removed until the belt
has been installed.
If you have ordered an open length, the steel
belt will be delivered in coil form, and welding
and partial polishing will be carried out once thebelt has been installed on your machine on-site.
There are advantages to each method but theopen length can be preferable if you have alarge machine requiring a long belt. Anotherfactor to consider is that the installation of anendless belt will require the removal of theentire machine side panel, whereas an open
belt can be installed without doing so, saving
time and money.
Your IPCO sales office can provide additional
advice and details of our field service.

6Tension pulley
For proper handling of belt
elongation in high temperature

Tracking device
With linear movement

Maximize your return on investment
A steel belt of any kind can represent a sizeable investment so it’s
important to maximize its profitable working life. Polished belts
are sensitive products so particular care needs to be taken.

Material supply

Drive pulleyWith appropriate
tracking device

Correct cleaning
Never use contact-type
cleaning devices• Never allow potentially damaging objects tocome into contact with the belt
• This may seem obvious but among the mostcommon causes of problems are machineparts coming into contact with the belt
surface or operators dropping tools onto thesteel belt.
• Ensure that the belt runs smoothly• Special attention should be paid to machinealignment, linear belt tracking and smoothsupport roller movement etc.
• Follow correct cleaning practices• Careful belt handling is required: everyoperator should be trained in propercleaning practices – under no circumstances
should contact-type cleaning devices be used
• Carry out planned maintenance• Prevention of problems is far more costeffective than repair. Even if problems are
sometimes unavoidable, early detection cankeep costly downtime to the minimum.
Our experience in the installation, maintenanceand repair of steel belts means we can offer
advice on aspects such as machine design,
cleaning, preventative maintenance andoperator training.

With proper maintenance and ongoingcare, you’ll protect your investment andensure a long and profitable life for yoursteel belt. Talk to us about how we can help
keep your belt at its most productive.

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Global support to keep yourbusiness running
Accidents do happen and the important thing is to ensurethat downtime is kept to the absolute minimum.

T----PRODUCTION-------DUCTION------SUPER--mirror---polished---SEEL------BELTS------------FOR---FILM/SHEET------In the case of minor surface scratches, it canbe possible to carry out repairs on-site and ourtrained technicians are equipped with the mostadvanced tools available.

ipco.com

04-2018

However, if scratches are deep or extensive, or
if on-site repair cannot be guaranteed to meetcritical thickness/surface tolerances, your belt
will need to be returned for factory repair. We
therefore recommend that all customers hold aspare belt. This may seem excessive but just a
few days’ lost production can equate to the costof a new belt.