The smart technology for every process

Achieving consistent flatness while preserving surface quality is a central challenge in aluminium strip processing. Thickness, material properties and line speed affect the levelling method, while the strip surface requires careful control of its contact with the working rolls.

FIMIGroup applies three levelling approaches according to the material and the specifications of the processing line: Pure Tension Levelling with PROFLEXROLL®, Tension Levelling and multiroll levelling with TDDS®. Each addresses a different combination of strip thickness, residual stress and surface requirements.

Pure Tension Levelling for thin aluminium strip

The Pure Tension Leveller (PTL) is designed for thin and ultra-thin material. It replaces the small yielding and levelling rolls of a conventional tension leveller with large-diameter rolls and a PROFLEXROLL® levelling roll. It can process material from 20 microns at speeds up to 500 m/min; the compact unit is approximately 4.5 metres long, including entry and exit bridles.

PROFLEXROLL® changes its external diameter to influence strip elongation locally where residual stress needs correction. The configuration is intended to achieve high flatness while limiting scratches, chatter marks and other surface defects. The use of large-diameter rolls also reduces the maintenance associated with small rolls.

Tension Levelling with controlled elongation

For thicker material, the FIMIGroup Tension Leveller (TLL) flattens the strip and helps equalize residual internal stresses through controlled elongation. Entry and exit bridles progressively raise strip tension to the required levelling level and then return it to line tension. A computerized system adjusts the relationship between bridle speeds using parameters including strip thickness, width, material characteristics and target elongation. The system controls constant elongation with a specified precision of 0.05%.

Surface protection is part of the machine design. ISOPAR lubrication helps keep aluminium oxides and dust off the working rolls and reduce the risk of scratches and marks. Cleaning devices remove contaminants from roll surfaces continuously or on demand, including during operation. For manual access, the lower roll bank can be extracted towards the operator and the upper rolls can rotate by 180 degrees. This allows working-roll cleaning without removing the strip from the machine.

TDDS® for multi-roll levelling and delicate surfaces

FIMIGroup’s patented Torque Dynamic Distribution System (TDDS®) is used in multi-roll levellers for high-strength steel and non-ferrous strip with delicate surfaces. Sliding couplings on the distributor output shafts let individual working rolls adapt their speed. The couplings operate continuously in an oil bath, distributing the levelling torque more uniformly among the rolls.

By reducing sliding between the working rolls and the strip, TDDS® helps protect the strip surface from scratches and supports longer working-roll life. This configuration does not require wet lubrication on the levelling rolls specifically to prevent scratches caused by roll-to-strip sliding.

Selecting the technology for the process

No single levelling configuration covers every aluminium application. FIMIGroup selects the system from strip characteristics, thickness, line speed and the process requirements of the line. PTL with PROFLEXROLL® addresses thin and ultra-thin strip; TLL manages controlled elongation in thicker material; TDDS® addresses roll speed and torque distribution in multiroll levelling. These technologies can be incorporated into dedicated equipment or complete strip-processing lines.

Technology	Application focus	Operating principle	Process objective
PTL + PROFLEXROLL®	Thin and ultra-thin strip	Pure tension levelling with adjustable roll diameter	Flatness with surface protection
TLL	Thicker strip	Controlled strip tension and elongation	Flatness and residual stress management
TDDS® multiroll	Multi-roll levelling	Individual roll speed adaptation and torque distribution	Reduced roll-to-strip sliding

 

Meet FIMIGroup at ALUMINIUM 2026

Discuss your aluminium strip processing requirements with the FIMIGroup team at ALUMINIUM Düsseldorf, 6–8 October 2026, Hall 3, Stand H21.
To arrange a meeting, write to marketing@fimigroup.it.