polyurethane v-rollers

polyurethane manufacture in USA

At LUC Group, we pride ourselves on delivering custom-engineered polyurethane components to meet the toughest demands across industries. One of our latest projects out of our Conroe, Texas facility showcases exactly that — a series of heavy-duty V-rollers designed for offshore spoolbase operations.

What’s a Spoolbase?

Spoolbases are shore-based facilities used to load and unload critical components — such as tubular steel, flexible pipelines, umbilicals, and other subsea equipment — onto vessels for offshore deployment. The rollers used in these setups must perform reliably under intense and often unpredictable conditions.

The Role of Our V-Rollers

Our polyurethane-covered V-rollers are installed in long tracks — often hundreds of yards in length — that guide and support the tubular product as it moves toward the vessel.

These rollers are exposed to:

☀️ UV and weather (as they’re used outdoors year-round)

🔥 Heat buildup from friction, speed, and heavy loads

🛠️ Wear and abrasion, especially if bearings fail or the product surface is rough

Why LUC Rollers?

At LUC, we don’t just build rollers — we engineer for performance and longevity:

✅ Custom polyurethane coverings using materials like LUCANYL or LUCPREEN for high wear resistance and strength

⚙️ Fast lead times and production out of our USA facility

♻️ Refurbishment services to extend equipment life and reduce cost

This combination allows us to deliver faster, last longer, and support sustainability in offshore operations.

A Big Thanks

Special thanks to our team in the U.S. for capturing these behind-the-scenes moments and making it happen!

polyurethane manufacture in USA
polyurethane v-rollers
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Products made of Vulkollan® and other custom-made elastomers  engineered for your most demanding applications.

At LUC Group, we are proud to make products of Vulkollan® — one of the most trusted and best‑known elastomer brands worldwide. Its proven performance, durability, and reliability make it a top choice for material handling, logistics, and high‑load industrial applications.

But our strength goes beyond Vulkollan®.

Vulkollan®: The Benchmark for Performance

As a licensed manufacturer of products made of Vulkollan®, we create custom‑made components that deliver:

  • Exceptional dynamic load capacity
  • Outstanding abrasion and tear resistance
  • Long-lasting mechanical stability
  • Reliability under continuous and intensive operation

Typical applications include:

  • Wheels and rollers
  • Drive & conveyor components
  • High-wear, high-stress mechanical parts

Every component is individually engineered to match your exact needs — no standard catalog, no off‑the‑shelf limits.

Alternative Materials for Even More Challenging Specifications

Some applications require something different — higher temperature resistance, different chemical conditions, extreme loads, higher speeds, or special engineering constraints.

That’s why we also offer alternative elastomer materials, developed and selected to meet:

  • More challenging environmental conditions
  • Specific technical requirements
  • Custom hardness, flexibility, or mechanical behavior
  • Special geometries or engineered performance

If Vulkollan® is the benchmark, our alternative materials give you the freedom to go beyond the benchmark when your application needs it.

100% Custom-Made

Regardless of the material, everything we produce is fully custom-made.  We design and manufacture components based on your drawings, your performance expectations, and the realities of your application.

Meet Us at LogiMAT 2026

If you’re visiting Stuttgart, we would love to meet you!

👉 Visit us at our stand: Halle 9 / Stand 9A25

See you at LogiMAT!

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Milling Discs

In TiO₂ pigment production, milling efficiency is key to maintaining consistent quality and cost‑effective operation. A leading TiO₂ producer in the UK operating a pressurised wet slurry mill was experiencing rapid wear on their milling discs, causing unstable particle size distribution and increased energy use. LUC Group collaborated with the customer to engineer a durable, high‑performance solution using advanced polyurethane technology.

The Challenge: High Wear in an Extremely Harsh Environment

The milling system relies on Zirconium beads and processes a TiO₂ slurry containing free chlorine — a combination that is both highly abrasive and chemically aggressive. This caused:

  • Premature disc wear
  • Reduced milling efficiency
  • Out‑of‑spec particle size
  • Increased power consumption

Traditional polyurethane grades struggled to withstand these conditions, leading to frequent maintenance intervals

The Solution: LUCANYL‑HB 90°A for Superior Wear and Chemical Resistance

LUC Group recommended upgrading the milling discs and spacers to LUCANYL‑HB 90°A, a polyurethane specifically engineered for:

  • Exceptional wear resistance

  • Strong chemical resistance, including free chlorine

  • High durability under high torque levels

  • Reliable performance in abrasive and pressurised slurry mills

This custom PU grade was developed to outperform generic polyurethane traditionally used in the industry.

The Results: Lifetime Extension Beyond Expectations

The improvement was significant:

  • The generic PU discs normally lasted up to 3000 hours
  • With LUCANYL‑HB, the system reached 14000 hours, almost 5 times the lifetime
  • The aluminium insert became the new weakest link, showing how far the PU component performance had advanced

This upgrade resulted in:

  • Longer maintenance intervals
  • More stable particle size distribution
  • Better milling efficiency
  • Lower energy consumption
  • Increased system reliability in harsh chemical environments

LUC continues to support the industry by exploring opportunities to upgrade the aluminium hub for even greater system durability.

Trusted in the Industry

This solution is already applied successfully at multiple TiO₂ pigment plants across the world, demonstrating its effectiveness in some of the harshest processing conditions.

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Support Wheels for Potato Elevator Drums

Introduction

This case study examines the challenges and solutions associated with support wheels for potato elevator drums in a food processing environment.

Problem

A manufacturing plant was facing issues with support wheels for a potato elevator drum. This large drum, fully submerged in process water with potatoes being elevated to an upper-level process water flow, rotates on 2 shafts with 4 PU-covered wheels each. Due to a combination of high load, axial movement of the elevator drum (due to poor alignment), and the aggressive process water, the original PU covering failed. The polyurethane layer detached from the wheel hub within one month of operation. The original wheels were provided with axial grooves for the submerged application.

Solution

The proposed solution was to increase the layer thickness by 100% compared to the original, switch to polyurethane LUCANYL-HB 90°A, and apply one radial groove in the middle of the running surface. LUCANYL-HB 90°A is a polyurethane with high traction properties for the driving application and a high load-bearing capacity, combined with high resistance against hydrolysis—three critical properties for this application.

The radial groove in the middle of the running surface allows the axial movement of the elevator drum without causing high material stresses in the polyurethane layer. Although LUCANYL-HB 90°A is not the typical FDA-compliant polyurethane (for which LUCTHAAN polyurethanes would be recommended), it was accepted for this application due to its inert nature and lack of migration in submerged applications with direct food contact. The polyurethane covering was made in blue (detectable) due to the food application.

The original 4 PU-covered wheels on 1 shaft were replaced by 2 LUCANYL-HB 90°A wheels on the outsides plus 2 nylon wheels (with a smaller diameter) in the middle. The LUCANYL-HB 90°A wheels provide driving properties without slippage, while the smaller nylon wheels serve as a safety measure in case of extreme deflection due to peak loads in the elevator drum.

Results

The lifespan of the polyurethane covering increased from 1 month to more than 12 months, showcasing the effectiveness of the LUCANYL-HB 90°A solution.

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Where Engineering Precision Meets Ocean Power

Offshore operations demand absolute confidence. When massive components travel across open seas—monopiles, heavy equipment, or specialized offshore structures—the forces acting on them are extreme. Wind, waves, vessel motion, and dynamic load cycles all create challenges that must be met with high‑performance engineering solutions.

High‑Friction PU Pads are one of the unseen heroes in this process: compact, engineered, and essential for safe seafastening. They ensure that cargo remains secure, stable, and protected throughout offshore transport—no matter the conditions.

The Purpose of High‑Friction PU Pads

During offshore transport, the interface between steel structures and support frames must remain reliable under dynamic loads. High‑Friction PU Pads provide:

  • Exceptional grip to prevent cargo movement
  • Controlled deformation that compensates for tolerances
  • Load distribution to protect both cargo and support structures
  • Surface protection to avoid coating damage
  • Consistent friction performance in harsh environments

Their purpose is simple: keep heavy components secure while absorbing the realities of offshore motion.

Material Excellence: What Makes PU Ideal for Offshore?

Polyurethane (PU) is an outstanding material for offshore conditions due to its:

  • High dynamic load‑bearing capability
  • Strong wear and abrasion resistance
  • Ability to achieve high friction levels
  • Resistance to saltwater, temperature variations, and humidity
  • Flexibility in shaping and embedding into seafastening designs

This combination makes PU ideal for pads used in marine, offshore, and heavy‑transport operations.

When Engineering Meets Harsh Seas

Offshore transport exposes cargo to:

  • Roll and pitch forces
  • Vessel acceleration
  • Slamming loads
  • Vibrations
  • Long duration fatigue cycles

In such environments, friction pads must not only hold a monopile or structure in place—they must maintain performance throughout the entire voyage, even under unpredictable weather dynamics. High‑Friction PU Pads absorb micro‑movement, spread load, minimize wear, and prevent coating damage—critical for ensuring structural integrity upon arrival.

Spotlight Application: Monopile Transport

Monopiles used in offshore wind foundations are among the largest structures ever transported by sea. Typical dimensions can include:

  • Diameters exceeding 9 meters
  • Lengths over 70 meters
  • Transport weights well above 1,300 tons

With components of this scale, the interface material plays a critical role. High‑Friction PU Pads:

  • Secure cylindrical monopiles in cradle structures
  • Protect painted surfaces from damage
  • Increase friction to prevent rolling or shifting
  • Absorb load variations caused by vessel motion
  • Ensure stable, predictable contact under massive weight

Their performance directly contributes to safe, efficient, and damage‑free monopile delivery.

Quality You Can Depend On

At LUC Group, each pad undergoes a rigorous production and finishing process that includes:

  • Hardness verification
  • Bond quality inspection
  • Curing control
  • Visual and dimensional checks
  • Final mechanical performance evaluation

This ensures every pad meets offshore‑grade performance requirements—reliable, stable, and capable of handling extreme loads.

Versatile Across Offshore Applications

Beyond monopiles, High‑Friction PU Pads are widely used for:

  • Seafastening of general offshore structures
  • Transport frames for heavy equipment
  • Upending and support tools
  • Temporary fixing systems
  • Heavy cargo stabilization on deck

Their adaptability and durability make them a trusted solution across the offshore energy and marine sectors.

A Small Component With Massive Impact

High‑Friction PU Pads may appear modest in size, but their contribution to offshore safety and reliability is significant. They combine material science, precision engineering, and offshore resilience—working quietly behind the scenes to ensure every journey across the sea is safe, stable, and predictable.

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Aluminium packaging is setting new standards for sustainability and performance in today’s manufacturing world. At the heart of this progress are advanced polyurethane rollers, engineered to optimize every step of the production journey.

The Production Journey—Where Precision Meets Innovation

Creating aluminum cans and bottles involves a series of carefully controlled stages:

  • Stamping thick-walled aluminium discs into precise shapes
  • Internal and external lacquering for protection and aesthetics
  • Multi-color printing to deliver vibrant, brand-ready designs
  • Finishing and automated packaging for consistency and speed

Polyurethane rollers are essential throughout these stages. Their customized hardness and dimensions ensure flawless priming, accurate ink application, and smooth finishing—supporting high-speed lines and consistent quality.

Materials That Make a Difference

Polyurethane stands out for its durability, chemical resistance, and ability to maintain exact tolerances under demanding conditions. These rollers are designed to handle a variety of inks and coatings, minimizing waste and maximizing efficiency. Their adaptability allows manufacturers to tailor roller specifications to the unique needs of each production line.

Products and Materials for Metal Packaging

  • Varnish rollers for base and top coat application (LUCTEC–CA)
  • Decorator / inking rollers for printing application (LUCTAN–CA)
  • Applicator rollers for base metal coating (LUCTEC–CA)

Advanced polyurethane technology not only boosts operational efficiency but also supports sustainability goals by reducing energy use and material waste.

Continuous Improvement

Success in packaging manufacturing relies on ongoing collaboration and innovation. Regular evaluation and the introduction of new roller solutions keep processes at the cutting edge, driving both reliability and product advancement.

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At LUC Group, we take pride in delivering polyurethane solutions that help drive innovation in the offshore energy sector. One of our latest contributions is the specially engineered polyurethane (PU) pad we developed together with Sif for the Skybox concept, to be used on future offshore wind projects.

The Skybox platform connects to a monopile foundation through a conical slipjoint – a clever system where two steel sections fit together, much like stacked coffee cups. While simple in theory, ensuring a secure, durable, and coating-protected connection in harsh offshore environments presents unique challenges.

That’s where our PU pads come in.

The Challenge: Stability, Durability, and Precision

Offshore structures face:

· Extreme loads from wind, waves, and equipment.
· Fabrication tolerances that can affect settlement and stress distribution.
· The need to protect steel coatings over decades of exposure.

Without the right interface material, these factors can lead to uneven load transfer, coating damage, or premature wear, compromising performance and lifespan.

The Solution: High-Performance PU Pads

Through extensive testing and collaboration with Skybox Offshore’s engineers, PU pads with a unique combination of material properties and geometry were developed:

· Material Performance:
Our proprietary polyurethane formulation balances flexibility and stiffness, ensuring strength and long-term durability while still being capable of compensating for fabrication tolerances by compressibility.

· Optimized Geometry:
Pads are designed to deliver:
   – Progressive stiffness (softer under light load, firmer as loads increase).
   – Even stress distribution to protect coatings and steel.
   – Predictable settlement behavior after installation.

· Proven Reliability: The material underwent rigorous testing by an external body for compression strength, friction, and aging under offshore conditions. These results fed into a material model, ensuring the pads meet stringent performance and certification standards.

Why It Matters

By combining cutting-edge polyurethane technology with precision engineering, our PU pads help ensure:

· Stable, predictable Skybox installation and operation.
· Protection of critical steel coatings.
· Durability over the full offshore lifecycle.

Every Skybox platform will integrate these PU pads engineered by Sif and LUC as standard components, supporting the growth of offshore wind infrastructure.

Partnering for the Future of Offshore Energy

With decades of expertise and a global footprint, LUC Group continues to be a trusted partner for offshore energy innovators. From friction pads and rollers to custom moulded components, our polyurethane solutions deliver performance, protection, and reliability in the harshest environments.

Further Reading

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OTC

Offshore Technology Conference

otc 2025

From May 5–8, LUC Group had the pleasure of attending the Offshore Technology Conference (OTC) 2025 in Houston, Texas. As one of the largest global gatherings for offshore energy professionals, OTC was the perfect stage to connect with partners, clients, and innovators in the industry.

With a growing portfolio of polyurethane components engineered for the toughest offshore environments, LUC Group was proud to be part of the conversation shaping the future of offshore energy. Our focus on high-performance rollers, tensioner pads, friction pads, and moulded parts for fabrication, shipping, and installation equipment for cable, pipe, and monopiles was met with great interest and enthusiasm.

From cable laying vessels to monopile installation, our custom polyurethane elastomers continue to prove their value in durability, resistance to harsh conditions, and reliability. OTC gave us the chance to exchange insights with key players and showcase how LUC materials like LUCOLLAN, LUCTEC, and LUCPREEN are tailored to meet offshore demands.

🙏 A special thank you to everyone we met and spoke with at the event. Your engagement inspires us to keep innovating.

💬 Interested in learning more about our polyurethane solutions for offshore energy? Don’t hesitate to contact us!

LUC Group team at OTC 2025 showcasing offshore polyurethane component
LUC Group team at OTC 2025 showcasing offshore polyurethane component
LUC Group team at OTC 2025 showcasing offshore polyurethane component
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bakery

As the global food industry continues to evolve, manufacturers face the challenge of balancing efficiency, hygiene, and compliance with ever-stricter safety standards. In this landscape, LUC Group’s high-performance polyurethane (PU) products have become an indispensable asset, particularly in specialized sectors like bakeries.

bakery

food industry

Why Polyurethane in Food Processing?

Polyurethane offers a unique combination of durability, chemical resistance, and hygiene — all essential in food industry equipment. At LUC, we engineer and manufacture PU parts designed specifically for the rigors of food handling and processing environments, including:

  • FDA Dry Food & Wet Food Compliant Grades
  • EU-Compliant Polyurethane Options
  • Resistance to Acids, Alkalines, and Cleaning Agents
  • Outstanding Wear Resistance and Load-Resilient Properties

Applications in the Bakery Industry

Bakery operations are particularly demanding, requiring materials that provide specific functional properties and are suitable for use in environments with flour dust, thermal variations, and direct contact with dough and food products. Our specialized materials — such as LUCTHAAN-FD and LUCTHAAN-FW — are engineered to meet these needs. Some of our key bakery-related applications include:

  • PU-Covered Rollers and Wheels for flour depositing and dough processing
  • Moulded Parts such as bowl scrapers and other bakery-specific components
  • Custom Components designed to integrate into bakery automation systems

Custom Engineering for Hygienic Excellence

Every application is unique — which is why LUC Group offers tailored design and material selection. With over 500 polyurethane material grades available and in-house capabilities including:

  • Design & Functional Analysis
  • Qualification Testing (Friction, Load, Speed)
  • R&D for Material Innovation
  • Refurbishment & Repair Services

— we ensure your bakery equipment not only lasts but excels in performance and hygiene.

Certified for Confidence

With ISO certifications (ISO 9001, ISO 14001, ISO 45001) and the ability to provide custom documentation including food compliance certificates, our clients can be confident that our PU solutions meet the strictest quality and safety standards.

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Polyurethane Elastomer Grades

Polyurethane Elastomer Grades

At LUC Group, materials are more than just components — they are the foundation of performance. With over 500 different polyurethane elastomer grades developed in-house, we offer unmatched flexibility and specialization to serve the most demanding industries.

Whether you need high load bearing capacity, chemical resistance, dynamic strength, high friction or low rolling resistance — we have a tailor-made material solution for your specific application.

💡 Choosing the Right Material Starts with Understanding Your Needs

We don’t believe in one-size-fits-all. Every application presents unique challenges — and we’re here to help. With decades of experience and deep knowledge of polyurethane chemistry, our team will guide you in selecting the optimal material for your design, environment, and performance goals.

🌟 A Selection of Our Key Polyurethane Elastomers:

LUCOLLAN
Designed for high operational loads, LUCOLLAN features low rolling resistance and outstanding wear properties — a top choice for high-performance drive wheels and dynamic applications.

VULKOLLAN®
As a licensed Vulkollan® manufacturer across all our global production sites, we proudly produce this renowned high-performance elastomer, known for its extreme load-bearing and dynamic capabilities.

LUCANYL
The ultimate material for extreme dynamic loads and high-temperature environments. LUCANYL offers superior resilience where standard polyurethanes would fail.

LUCPREEN
A versatile, classic high-performance elastomer, LUCPREEN performs well in both static and dynamic applications across various industries.

LUCTHAAN
An exceptionally versatile polyurethane, LUCTHAAN is ideal for niche applications that require unique performance characteristics, including food-safe formulations.

LUCTEC
Engineered for high friction environments, LUCTEC also combines high mechanical strength with excellent solvent resistance, making it perfect for drive rollers and traction components.

LUCHYD
A breakthrough in polyurethane innovation — LUCHYD is resistant to strong acids and alkalis, even under dynamic loading conditions and at high temperatures, offering long-term durability in harsh chemical environments.

LUCOCEL
A high-end cellular polyurethane elastomer that is water-resistant, with outstanding resilience and strength — ideal for cushioning, sealing, or damping solutions.

🛠️ We Also Offer High-Performance Rubber Grades

In addition to our extensive polyurethane range, we also offer various rubber materials, including:

  • Nitrile, HNBR, SBR, Natural Rubber
  • Hypalon, EPDM, Chloroprene
  • Silicone and Fluorocarbon (FKM)

🛞 More Than Just Materials — Complete Polyurethane Solutions

At LUC, we don’t just supply materials — we manufacture custom-engineered products:

Every product we make is fully customized, from the material selection to the final shape and finish — ensuring top performance in your application.

Polyurethane Elastomer Grades
Polyurethane Elastomer Grades

🧪 Need Help Choosing the Right Material?

With over 50 years of experience in material science, our team is here to help you choose the ideal elastomer based on your industry, application, and environment.

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