GESADUR® is a highly compressed thermosetting composite material containing approximately 60% natural fibre, developed specifically for heavy-duty support rollers in industrial machinery. During the curing process the thermoset forms a three-dimensionally cross-linked structure, which is what gives the finished roller its ability to absorb enormous forces without deforming permanently. The result is a homogeneous, extremely compact and practically incompressible material with a density of around 1.37 g/cm³ and a compressive strength of approximately 300 N/mm². Unlike layered or moulded laminates, GESADUR has no internal ply structure, so there are no weak planes along which the material can split under sustained load. Because it is built on a renewable natural fibre base, it also offers a more sustainable alternative to fully synthetic engineering plastics without sacrificing mechanical performance. In the wire and cable industry it has become the reference material for trunnion rollers, support rollers and under rollers, and it is equally established in metal spinning, annealing and strip processing applications.

Their function is to carry the full weight of a large rotating assembly and allow it to turn smoothly, quietly and concentrically at production speed. In the wire and cable industry this means supporting the rotating parts of stranding machines, where weights can reach many tonnes and the assembly runs continuously for long production campaigns. In these positions the roller is the interface between an enormous rotating mass and the machine frame, so any imperfection in the roller translates directly into vibration, noise and bearing wear across the whole line.

In many installations, yes. Because GESADUR is homogeneous and can be machined to a smooth, deposit-free running surface with high concentricity, the rotating assembly runs truer than it does on layered or worn rollers. Operators who convert from laminated fabric rollers frequently report that the rotational speed of the machine can be increased while running noise is simultaneously reduced — an unusual combination, since speed increases normally make machines louder. The material also provides genuine damping of vibrations and oscillations rather than transmitting them straight into the frame, which protects machine bearings, fasteners and foundations over the long term. Higher achievable line speed means higher output per shift from existing equipment, so the roller upgrade is often evaluated as a productivity investment rather than a maintenance cost. Actual gains depend on the machine, the load and the condition of the rest of the drivetrain, and we are happy to review your specific setup before you commit.

GESADUR combines high impact strength, high compressive strength of approximately 300 N/mm² and a comparatively low specific weight of around 1.37 g/cm³, so rollers are strong without adding unnecessary rotating mass. Electrically, the material is an insulator with good dielectric properties, which matters wherever rollers must not create a conductive path through the machine, and it can be made antistatic with the appropriate surface treatment. It is resistant to oil and grease, water- and oil-repellent and has low water absorption, so performance does not drift in humid or contaminated workshop conditions. Thermally it offers a high flash point, good heat insulation and dimensional stability at elevated temperatures. It is climate-stable, tropic-resistant and termite-resistant, and it does not age in storage, which makes it well suited to spare parts held on the shelf for years. The natural beige colour darkens under UV light without any loss of quality or mechanical performance.

We supply replacement support rollers for essentially any machine that runs on this type of under roller, including tubular stranding machines, planetary stranding machines, and drum twisters. This covers equipment from manufacturers such as Stolberger, Queins, Setic Pourtier, Flymca, Bartell, Roteq, Lesmo, Ceeco, Mali, Cortinovis, Caballé, MFL and SKET, along with many other builders whose machines are in daily use in wire and cable production lines worldwide. Because rollers are made to dimension rather than to a fixed catalogue, compatibility is determined by geometry rather than brand — if we have the outer diameter, width, bore and hub arrangement, we can supply the part. This is particularly relevant for older and discontinued machines whose original manufacturer no longer supports them, and for lines assembled from equipment of several different origins.

Service life depends on load, line speed, duty cycle, ambient conditions and cleanliness, so no single figure applies to every installation. What is consistent is that GESADUR substantially outlasts laminated fabric rollers in the same position, because it does not delaminate under sustained pressure and does not flatten when the machine stands still under load. The practical indicators that a roller is reaching the end of its life are audible change in running noise, new vibration, visible surface burning or scoring, and measurable loss of concentricity. Because a failed under roller can stop an entire stranding line, we recommend treating rollers as planned-replacement consumables rather than run-to-failure parts: hold spare rollers or pre-machined blanks in stock, replace them during scheduled maintenance windows, and keep a record of running hours per position. The cost of a spare on the shelf is almost always lower than the cost of a shift of unplanned downtime.

Yes. All GESADUR rollers are available with worldwide shipping, packed to international standards so that parts arrive undamaged and ready for immediate installation. Our technical team supports the whole process, from part identification and dimensional measurement through to specification of the bush or sleeve arrangement and advice on machining and installation. If you are unsure exactly which roller you need, send us the machine details and dimensions or a picture, and we will confirm the correct part before you place the order.