This article will give detailed information on cylinder brushes regarding:
Cylinder brushes are commonly referred to as "coil brushes," "rotary brushes," or "spiral brushes." They are created by wrapping a metal strip around a cylindrical rod (or mandrel) until the desired interior brush diameter is achieved.
These brushes often feature bristles made from a variety of materials, such as flexible synthetics, soft natural fibers, metal wires, and strong yet lightweight polymer materials. The bristles are either stapled, glued, or knotted in a pattern perpendicular to the core's axis through holes drilled into the mandrel. The arbor hole at the center of the core allows users to insert a shaft, enabling the cylinder brush to be attached to a motor and spun mechanically around its axis. The specific construction technique for a cylinder brush depends on factors like the required number of bristles, the operating RPM, and other brush characteristics.
Ironically, "fill material" refers to the bristle material attached to the exterior of a cylinder brush. Various materials are used as fill, each with unique strengths suited to different applications. Below, we explore some of the more popular fill materials for cylinder brushes and their specific advantages.
Proex®: Proex is made from synthetic resin polypropylene and features an X-shaped filament, unlike pure polypropylene. This X (horizontal) and Y (vertical) profile increases the effective cleaning surface area by nearly 25% compared to pure polypropylene, enhancing dust pick-up. Proex delivers excellent sweeping performance in both indoor and outdoor settings, including wet or humid conditions, and offers a long wear life. However, it is not recommended for applications involving very high temperatures, such as foundries.
Polypropylene: Polypropylene is a synthetic thermoplastic polymer that features good chemical and fatigue resistance. Polypropylene provides good sweeping performance in indoor and outdoor settings, even in moist or humid conditions. Polypropylene is not advised for high-temperature applications. Polypropylene is inferior to its Proex offshoot for picking up fine particles. However, polypropylene is still effective in below-freezing temperatures. Polypropylene does pick up larger, heavier particles quite well. The wear life of polypropylene is good.
Nylon: Nylon, compared to polypropylene, offers a less aggressive sweeping performance and is less effective in damp environments. It is often used on rough outdoor surfaces or in high-temperature situations due to its hardness and durability, handling temperatures up to 150°C (over 300°F) in foundries. Nylon is known for its excellent wear life.
Organic Fiber: While natural fibers wear out more quickly than synthetic materials, they are highly effective for sweeping fine debris and controlling very light dust. They are not recommended for use on damp floors due to their lack of waterproofing. Organic fibers are ideal for sweeping carpets as they do not generate static electricity.
Goat Hair: Goat hair is exceptionally soft and fine, making it ideal for short, supple brushes used in electronics.
Horsehair: Horsehair brushes are well-suited for delicate dusting, cleaning, and polishing tasks.
Wire & Polymer: The wire in this brush provides a gentle cutting action for eliminating compacted dirt or muck, while the polymer gives it exceptional all-purpose sweeping capabilities. Wire and polymer cylinder brushes have short wear lives. Although polymer & wire brushes have a short wear life, they offer excellent dust control.
Wire and Proex®: This brush combines the versatility of Proex with the wire's gentle cutting action, making it effective for general sweeping tasks and removing impacted dirt or mud. However, wire-containing brushes are prohibited in food manufacturing facilities and airports due to health and safety regulations. The wire typically wears out before the Proex component, but overall, this brush type offers a decent wear life.
PBT Polyester: Although more expensive than nylon, polyester is firmer, offers superior flick action, and performs better in damp or wet conditions. Polyester also has a comparable lifespan to nylon. Large diameter (over 0.8mm) polyester filaments in cylinder brushes typically start to show wear after about 120 hours of use. PBT polyester is known for its excellent wear life.
Cylinder brushes are used in numerous industries to clean equipment. Cylinder brushes are used to clean the fruits and vegetables we eat. Without thinking about it, we encounter cylinder brushes in our daily lives as they perform work at our car washes and in our vacuum cleaners. Cylinder brushes can be produced with a very thick brush filling or a spiral shape for applications that require light brushing or product directionality, and they are simple to attach onto shafts.
Wound brush construction is a flexible design used in both small and big-diameter cylinder brushes. The core of wound brushes is made of steel, aluminum, brass, stainless steel, or plastic, and an acme screw thread-like groove is carved into it helically. The filaments are then drawn into the core by a stainless steel holding wire secured at both ends. The fact that the filaments and the retaining wire are recessed into the core is an advantage of this design as it makes refilling simpler and enables smaller outer diameters. Epoxy wound brushes are ideal when greater RPMs (revolutions per minute) or balancing are necessary because they have integral cores which can be mounted on a shaft, and they don't wobble. First, directly wound filaments are secured to the shaft with epoxy before curing. Then, brushes can be taken out, and shafts can be repeatedly wound. Due to their distinctive brush-wound shape, filament contact is consistently provided by a uniform distribution of filaments over the brush’s surface. The intended use of a brush always dictates the bristle material choice. For instance, a spiral brush used to remove burrs must be made of a sturdy metal that won't rust significantly or easily when coming into contact with another metal.
Steel wire offers the highest fatigue life and longest cutting action among commonly available brush wires. Steel wire cylinder brushes are the most cost-effective metal brush option and are suitable for various applications. While they can be used on wood, concrete, and other softer metals, they are ideally suited for steel and ironwork. Generally, a steel wire brush is more likely to cut into and remove both base material and any targeted coating or contamination, particularly when working with softer materials during the brushing action.
Heat and Moisture: Steel wire cylinder brushes can handle brief contact with temperatures up to 275°F. However, they are not suitable for environments with high humidity or moisture due to corrosion risks. These brushes are ideal for cleaning large surfaces or conveyors in manufacturing settings. Modern technology allows for the customization of steel wire cylinder brushes to meet specific application needs.
Steel cylinder brushes are versatile and can be used for a variety of purposes, including:
Stainless-steel wire cylinder brushes are well-suited for working with stainless steel and aluminum, applications involving direct food contact, environments with higher temperatures than those suitable for steel wire brushes, and settings where the brush wire is often exposed to moisture or high humidity. Stainless-steel wire can generally handle continuous operation at temperatures up to 600°F. For temperatures exceeding this threshold, a more specialized wire, such as Inconel®, is required.
Brass wire cylinder brushes are softer than those made with steel or stainless steel wire, offering a brushing action that is less likely to damage harder metals. Brass wire, an alloy known as Alloy 260 with 30% zinc and 70% copper, is a good choice for working with brass or copper workpieces. Brass wire, along with bronze wire, does not produce sparks when striking other metallic surfaces, making it suitable for potentially hazardous environments. Additionally, brass wire, with its 28% conductivity, is effective for static-reduction applications when used in brass, steel, or stainless-steel channel backings. Brass wire brushes are suitable for operating temperatures up to 300°F and are relatively resistant to corrosion.
Cylinder brass brushes are well-suited for wide-surface brushing or cleaning in industrial environments, such as conveyor cleaning or surface roughening to enhance adhesion. Like other metal filament cylinder brushes, brass cylinder brushes can be customized for specific applications. They are designed for various cleaning purposes, including:
Staple-set cylinder brushes are made by drilling holes into a cylinder in a specific pattern based on the application's requirements. Filaments are inserted into these holes in a U shape, and a staple is placed over the bottom of the folded filaments to secure them to the cylinder. While some of these specialty brushes can be handcrafted, automated manufacturing equipment is also used for large-scale production. Specialty applications may require unique filament patterns, such as lightly filled brushes, auger patterns, or straight rows with specific spacing. Staple-set cylinder brushes typically feature a plastic core and are ideal when a lighter-weight cylinder brush is needed.
Typically made with two, and occasionally four, wires, twisted-in-wire brushes are created by securing the filament on one end while twisting the wires together on the other end. This process causes the filament to wrap around the wires, forming the brush. Often featuring a portable stem or loop, these specialized brushes are sometimes called stem brushes. They are used for cleaning test tubes, equipment with holes, and other items. While commonly employed in motorized applications, twisted-in-wire brushes are also useful for hand-held tasks, such as deburring machined holes. They can clean freshly machined components or used parts to remove dirt, residue, or coatings and prepare items for painting, powder coating, or anodizing. Although wire filament is the most common material, twisted-in-wire brushes can also be made with various organic or synthetic materials.
External cylindrical coil brushes are commonly found in vacuum cleaners, street sweepers, and industrial compound applicators. These brushes consist of a long strip of bristles coiled spirally to form a cylinder. They can vary in diameter and length based on the specific task they need to perform. Some external cylindrical coil brushes are tightly twisted to resemble solid cylinders, while others may feature gaps depending on the application. Both spiral-wound cylindrical brushes and coil brushes fall under the category of cylindrical coil brushes. They are used in a wide range of applications, from very small tasks like condenser tube cleaning to very large ones like glass washing. Their uses include dusting plywood, cleaning condenser tubes, processing photos, and more. They are also employed for dusting, polishing, deburring, and other cleaning tasks. Internal cylindrical coil brushes can serve as drills to move products in a given direction and are versatile for various applications including cleaning, deburring, and polishing.
In manufacturing, bronze wire cylinder brushes are employed to clean conveyors or to brush the wide surface of a substrate. Spiral-wound bronze cylinder brushes, based on strip brush technology, are specially designed to meet specific user requirements. Similarly, paddle wheel-style bronze conveyor cleaning brushes utilize strip brush technology and feature a refillable brush core. Bronze wire cylinder brushes are versatile and can be used for various purposes, including:
Bronze wire is stiffer and tougher compared to brass wire. Phosphor bronze wire, Alloy 510, which consists mostly of copper (95%) and tin (5%), is used in bronze wire. The addition of tin enhances the fatigue strength and tensile strength compared to C-260 brass wire.
Bronze wire is suitable for hazardous areas as it typically does not spark when struck against other metallic surfaces. When used in a wire strip brush with a brass or steel channel backing, bronze wire, with its good electrical conductivity (15 percent IACS), is appropriate for static-reduction applications. Additionally, bronze wire can withstand operating conditions with steady temperatures up to 400°F and is relatively resistant to corrosion.
Spiral-wound bronze cylinder brushes are usually mounted on a shaft or a tubular core. The brush strips are coiled around the arbor and fastened with the appropriate density or spacing.
Conveyor cleaning brushes with tight coiling offer a dense brush surface for consistent cleaning over a wide area. Open-wound brushes, featuring gaps or pitch between the rows of helically-wound brush strips, help move loose products or debris to one side, both sides, or the center.
Bronze cylinder brushes come up to 20 feet long, with outside diameters ranging from 1-5/8" to 45" and interior diameters from 1/2" to 30" or bigger. Galvanized steel, stainless steel, brass, and aluminum are available for strip channels. Steel, stainless steel, or other materials suited for a specific application may be used to make the shaft or core onto which the brush will be placed.
Circular nylon-filled brushes are commonly used for scrubbing, dusting, and cleaning conveyor belts that move items through factories. They are also employed in plating processes for metal coating, timber mills, and block and brick manufacturing, among other applications. Typically, nylon cylinder brushes offer the following qualities: good abrasion resistance, low to moderate water absorption (between 3 and 9 percent), excellent bend recovery, resistance to most common solvents, and suitability for use in weak acids.
Nylon 6.6 absorbs moisture at a rate of 9%, which is higher than the 8% rate for nylon 6.12. Consequently, nylon 6.6 loses nearly half of its rigidity when exposed to moist environments. It also offers limited resistance to various common chemicals. In contrast, nylon 6.12 has been approved by the FDA for direct food contact. Additionally, heat-stabilized nylon undergoes post-extrusion treatment to enhance its temperature tolerance before physical properties begin to degrade. For static reduction applications, both 100% load and reduced 20% load conductive nylon options are available to manage costs. Conductive nylon can also be combined with different brush fill materials to improve brushing functionality while reducing static charges and overall expense.
Abrasive nylon is a durable filament used in powered brushes for deburring, surface finishing, edge blending, and radiusing (rounding sharp corners) after machining. Examples of abrasive nylon power brushes include wheel brushes, cup brushes, end brushes, and powered cylinder brushes.
Polyester filament is used in cylinder brushes when polypropylene or nylon are unsuitable for the environment or application. Polyester has a slower water absorption rate, making it more rigid when wet compared to nylon, though still less stiff than polypropylene when dry. It has a higher melting and softening point than polypropylene and exhibits better memory or bend recovery. Polyester generally maintains its physical properties better than nylon and polypropylene at high temperatures, though it is more costly than polypropylene but less so than nylon. Special-order FDA-approved polyester versions are available. Polyester cylinder brushes offer superior resistance to moderate acids compared to nylon. Nylon 6.12, however, is highly resistant to substances such as acetone, benzene, ethyl acetate, hydrocarbons, methyl ketones, potassium hydroxide, sodium hydroxide, and toluene.
Polypropylene cylinder brushes are versatile and suitable for various applications, from vigorous scrubbing to mild dusting, depending on the brush type, filament size, and trim length. They are particularly effective in humid environments where consistent brush head stiffness is essential. Typical uses include conveyor cleaning, fruit and vegetable washing, and water-based part washing in sanitation-sensitive or challenging environmental conditions.
Polypropylene cylinder brushes offer strong chemical resistance to acids, corrosive alkalis, and many solvents, with the exception of trichloroethylene hydrocarbons, benzene, carbon tetrachloride, chlorine, and camphor. However, compared to nylon or polyester, polypropylene filaments degrade at lower temperatures (225 ° F) and melt at lower temperatures (330 ° F).
Custom cylinder brushes made from Tampico fiber and other natural vegetable fibers are available for spiral brushes. Tampico fiber, sourced from the wild agave lechuguilla plant in Mexico, provides superior water absorption and retention compared to synthetic filaments. Tampico cylinder brushes can operate in wet conditions up to 400 °F and offer strong heat resistance, surpassing many synthetic materials. These brushes are suitable for both wet and dry cleaning methods, including scrubbing, washing, polishing, and dusting. Tampico fibers can also be treated to enhance their stiffness and tackiness, making them effective for applying abrasive or grease-sticking materials.
Tampico cylinder brushes can serve as driven scrub brushes for removing loose material or as applicators for wet or dry coatings when mounted to interact with transported products. Tampico brush strips can be used for in-house refilling in cylinder brush assemblies, such as in paddle-wheel designs for conveyor cleaning or polishing applications. When wrapped around a shaft, a Tampico-filled strip brush becomes a versatile scrubbing or polishing tool with a broad face, ideal for covering large work surfaces.
Recently, synthetic alternatives to cylinder Tampico brushes have been introduced. When choosing brush fill materials, it's essential to evaluate these synthetic options to find the most suitable material for your specific application.
24 SR – 24 Single Rows: This brush features 24 tufts, or clusters, of fibers arranged around its diameter, and is often referred to as a "full fill" brush. It is highly effective at sweeping up high concentrations of dust, sand, soot, and similar small particles but is less effective for bulkier debris. The longevity of a 24-row brush is determined by its usage frequency rather than the number of bristles, meaning that a high-density 24-row brush will last as long as a 6-row or 8-row brush if used under similar conditions.
The 6 or 8 Double Row Helical Pattern (6. DRH or 8. DRH): The 6 or 8 double row helical pattern is one of the most common brush fill designs for primary sweeping applications. The spiral arrangement of bristles enhances the brush's ability to pick up debris. This versatile design is effective for sweeping both small and large particles. The rows of bristles capture finer materials, while the gaps between the rows collect larger debris. The DR pattern is widely favored for its ability to handle a range of waste types, making it a popular choice among users. All fill materials are available in this pattern due to its effectiveness with both small and bulky trash.
Herringbone (or Patrol Pattern), with 6 Double Rows or 5 Triple Rows of Chevrons (DRC or 5. TRC): The 6 double row or 5 triple row chevron (herringbone or patrol) pattern is a popular brush fill design for exterior sweeping applications. Its "V" shaped row arrangement is engineered to direct dirt towards the center of the hopper, facilitating fast and efficient sweeping. This pattern, featuring fewer rows with wider gaps, is particularly effective at capturing larger debris like leaves and large particles. It is well-suited for routine maintenance of large areas such as outdoor parking lots. Typically, this design is filled with nylon to ensure durability and long service life.
"WWW," or "Sand Wedge": The "WWW" is a high-density brush characterized by a zig-zag pattern of "WWW" and open spaces. This design enhances its ability to clean deep accumulations of small debris more effectively. It has the same amount of fill material as a conventional high-density brush and is especially effective in environments with concentrations of fine materials, such as sand or gravel.
"Flip Flap," or "Window": The "flip flap" brush is a specialized design with exposed "windows" that are effective at collecting light debris, such as paper fragments, which can be difficult to remove with other brushes. It works particularly well on smooth floors.
Cylinder Scrubs: Cylinder scrub brushes come in materials such as polypropylene, polyester, nylon, and abrasive nylon, and can be up to 60" (1524 mm) in length. These brushes are primarily used for removing rubber imprints and heavily compacted dirt.
Shaft: Shafts may include keyways as needed for drive applications. Metal clips can be attached to the shaft to secure steel cylinder brushes or be directly welded to it. Brushes mounted on a shaft are generally refillable, provided the shaft remains in good condition.
Throw-Away Core: Cylinder brushes can be mounted on an inexpensive, thin-walled tube with end bushings that attach to a drive shaft, making replacement easy. Instead of keeping a spare brush while waiting for the worn brush to be returned for refilling, you can simply order a new brush and install it in place of the old one.
Refillable Core: A refillable core is made from heavier wall tubes and can be refilled multiple times, offering a more durable and cost-effective solution. This design often features detachable shafts for easy replacement, avoiding the need to recreate the shaft or core by simply refilling the existing core.
Dynamic Balancing: Dynamic balancing may be necessary for cylinder brushes operating at higher speeds, typically between 350 to 500 revolutions per minute, to reduce vibration and improve brushing consistency. This is particularly important for brushes with larger sizes and weights to ensure smooth operation.
Cylinder brushes have a wide range of industrial applications. For example, they can simplify machine cleaning tasks and effectively remove chipping, rust, and grease debris. Smaller, more delicate cylinder brushes are used for precision tasks, such as pre-installation cleaning of computer circuit boards. These brushes reach into the board's crevices to remove particulates, dust, and other impurities. Below are some common industrial uses for cylinder brushes:
Food-processing brushes are most commonly used for the following purposes:
Cylinder brushes have numerous industrial applications, including but not limited to the following:
Cylinder brushes offer several advantages over other types of brushes, including:
Cylinder brushes offer several advantages over other brush types. Unlike pads, cylinder brushes do not tear or require recentering and do not necessitate expensive laundering. They use 20–30% less water and avoid the problem of squirting cleaning agents onto baseboards and walls, as is often needed with pads. Additionally, there are cylinder brush cleaning machines designed to clean edges and corners more effectively than round pad machines by being placed directly on baseboards. Cylinder machines operate at a quieter level of just 67 dBa (decibel noise level), making them ideal for environments with noise restrictions, such as healthcare facilities, nursing homes, and educational institutions.
Machines equipped with cylinder brushes provide floating head pressure that is about six times greater than that of standard disc units. This floating head allows for more consistent full-floor contact, enabling the brush to adapt to both high and low areas, making it more effective on uneven flooring and in spaces with varying textures. While pads may simply pass over grout and texture lines, cylinder brushes are capable of reaching and cleaning these areas effectively.
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