Union RollersSteel-to-Steel Embossing Applications

Global Leader in Precision Steel-to-Steel Embossing

At gravion, we set the global benchmark for steel-to-steel embossing technology.
Our Union Rollers embody pure precision — engineered for industries where accuracy, durability, and design excellence define performance.
From the smallest detail to the largest production scale, we ensure your embossing tools run with uncompromising perfection.

Steel-to-Steel ExpertiseWhere Precision Meets Performance

Many of today’s high-speed embossing tools operate in steel-to-steel configurations — whether positive/negative, positive/positive, or point-to-flat.
Gravion’s deep expertise in precision roller manufacturing allows us to master them all.
No matter the complexity or required precision, our technology guarantees stable performance, sharp definition, and long-term durability at full production speed.

We support a wide range of industries including:

Cutting industry
Strapping band manufacturing
Napkin and handkerchief production
Paper and packaging industry
Heat shield embossing
Plastic film and bag production
and any custom steel-to-steel embossing solution your process requires

Every roller we build carries gravion’s signature: micrometer-level precision and flawless concentricity.

gravionDimensions & Capabilities

Our steel-to-steel embossing rollers cover a wide dimensional range:

Engraving width: 10 mm up to 3500 mm
Total length: up to 4250 mm
Diameter range: from 42 mm up to 520 mm

Each roller is engineered and balanced to ensure zero vibration and perfect alignment – even in high-speed production environments.

Finishing for HardeningSpecial Treatments for Maximum Durability

We continuously develop surface treatments and hardening technologies together with our partners to extend the lifetime of your tools —from 1,000 Vickers hardness up to 4,500 Vickers.
These treatments ensure less wear, longer running times, and higher process reliability.

For details or specific surface technologies, contact our global gravion sales experts.

Union Rollers by gravionTechnical Advantages at a Glance

Our Union Rollers can be produced for:

Single-high, double-high, or triple-high steel-to-steel applications
Embossing depths from 0.005 mm up to 6.0 mm
Any design geometry, from delicate micro-engraving to deep, structural embossing

Each roller undergoes full concentricity and balance checks using state-of-the-art measurement systems – ensuring flawless operation and perfect replication of your embossing patterns.

Technology & PerformanceEngineered Balance

Precision and durability define the core of our Union Rollers. Each component is crafted to achieve flawless alignment, stable pressure, and seamless interaction between layers. The result: consistent performance, reduced wear, and a perfectly balanced production flow.

Perfect harmony in motion – Union Rollers aligned with absolute precision, positive and negative in flawless balance.

Framed in steel, united in detail – the art of pairing positive and negative embossing forms.

Precision is not coincidence – it’s the union of two perfectly matched forms.

The strength of a Gravion Union lies in symmetry – engineered frames ensuring flawless registration.

Custom EngravingEvery Idea Deserves its Perfect Texture

We develop custom-made embossing rollers, precisely tailored to your product’s functional and aesthetic goals. Through our direct laser engraving, we achieve micron-level accuracy, ideal for industries demanding absolute control — from hygiene and tissue to automotive, packaging, and specialty materials.

Your design, our precision — unlimited by tools, defined by imagination.

Design & Development

Innovation begins long before the engraving starts. At Gravion, design and development form the beating heart of our process. We act as your creative and technical sparring partner, transforming ideas into engineered perfection. Using 3D modeling, texture simulation, and iterative prototyping, we refine every pattern for maximum embossing performance and optimal material flow.

Systems

We provide integrated embossing systems in collaboration with trusted partners — ensuring seamless compatibility from mounting to control integration.
Our complete setups are engineered to boost throughput, reduce downtime, and maintain flawless embossing consistency across materials and environments.

Life Cycle Management

A Gravion roller is not just built to perform — it’s built to endure. Our Lifecycle Management Program covers every phase: from production and precision refurbishment to re-engraving and recycling. This holistic approach extends the lifetime of your tools, maximizes ROI, and contributes to a circular, sustainable production chain.

Precise embossing for your industryThese Industries Are Already Benefiting Today from Our Revolutionary Laser Technology

Exceed your expectations with our embossing rollers. gravion is the innovative embossing roller manufacturer for all industries that rely on precise, fast, and clean embossing results.

Aluminum Industry

Finish aluminum foils for applications in the packaging, automotive, shielding and foodstuff industries. A variety of material thicknesses can be used – our technology does not limit the possible material thickness. Our customers also enjoy complete freedom when it comes to the design.
With our innovative technology, we can create embossing structures with a depth from a few micrometers to four millimeters.

Automotive Industry

Create embossing structures for your leather and artificial leather applications, as well as embossing aluminum for cars, trucks, buses and other applications. There are no limits for the variety of embossing designs we can produce. Embossing structures for leather and artificial leather applications are usually lasered into copper surfaces. For aluminum embossing structures in the automotive industry, we laser the structures into hardened surfaces, with a range of different materials available for the customer to choose from. gravion is able to meet any requirements relating to the degree of gloss or other technical framework conditions.

Coatings Industry

From single to triple structures, for toilet paper, kitchen towels, napkins, interfolded sheets, tablecloths, and away-from-home products — we ensure superior precision across all applications.

Stainless steel Industry

The stainless steel embossing industry is incredibly varied, as are the potential roller sizes used. We are able to manufacture small rollers with widths as small as 50 mm, as well as special rollers for Sendzimir embossing rollers. We laser embossing rollers with extremely hard surfaces, including HSS steel rollers, on the sanded surfaces after a corresponding finishing process.

Lid Industry

Produce and finish hygienic films and screen films to your exact requirements using our rollers. We can produce everything from extremely delicate structures to 3D structures measuring over 1000 micrometers in depth without a problem.

Gift wrap Industry

The gift wrap industry is a niche sector, but one that gravion also supplies. Our design freedom and ability to directly laser machine steel are an incredible help for this very specialized sector. gravion's unrivaled abilities in this industry include embossing structures for aluminum, paper and composite materials. We are also more than happy to perform test embossings in advance, which are created on rubber or paper on our in-house test rollers.

Glass Industry

Use our technology to manufacture embossing rollers for technical glass, design glass and Plexiglass. These can also be lasered into hardened surfaces. Designs can be created at any depth up to 4 mm for the glass sector.

Plastics Industry

gravion manufactures all embossing rollers for any design in the plastic plate, plastic panel and plastic border industries. In this sector, our innovative technology is replacing conventional manufacturing methods, as well as applications in steel and copper surfaces.

Leather Industry & Artificial Industry

gravion produces all embossing rollers for the leather and artificial leather industries. These applications are typically embossed in copper surfaces.

Furnishings Industry

gravion is the perfect partner when it comes to surface embossing for the furnishings industry. We can create any design for your surface embossing structure.

Paper Industry

For businesses that use embossing rollers to emboss paper, gravion is the right choice – the perfect future-oriented partner. We are capable of producing linen embossings, worm-shaped embossings, damask embossings, pyramid embossings, handmade paper embossings, and playing card embossings. We are setting new standards when it comes to implementing new design possibilities. Our outstanding precision helps our customers to reduce the contact pressure against the counter rollers and to significantly increase movement speeds.

Pharmaceutical Industry

Seal grids in a range of designs are used in the pharmaceutical industry; gravion is able to manufacture these using the company's laser technology. gravion is also capable of producing these delicate structures in a standardized manner. Existing designs are transferred into the digital world using 3D scans.

Wallpaper Industry

gravion is able to manufacture embossing rollers for the wallpaper industry. We directly laser steel or copper surfaces, depending on the customer's request. Our employees in the digital data production team are on-hand to draw up every design detail. If requested, we are also able to create a cut-off embossing design.

Tissue Industry

The tissue industry is one of the largest sectors to use embossing rollers. gravion's innovative technology is ideal for any application in this industry. We are able to create single embossings as well as double or even triple embossing structures. The embossing rollers can be manufactured as single embossing rollers or as positive/negative embossing rollers made of lasered normal steel or hardened steel. Our unique technology enables us to achieve significantly higher precision and to create embossings at any depth required in this sector.

Strapping Industry

The embossing rollers sets needed in the strap industry, which are typically positive/positive sets, are manufactured to the highest standards of precision and accuracy using our innovative technology; gravion is able to supply and adjust designs of any kind. For a dedicated development partner in this sector that can offer you unlimited freedom for future designs, look no further than gravion.

Packaging Industry

Working with customers in the packaging industry is one of gravion's many strengths. For embossing rollers designed to emboss lettering on paper or rubber, or for union sets (positive/negative) for the lid embossing industry or logo rollers for aluminum packaging. All existing structures in the union roller industry can be implemented using gravion's innovative technology.We are also more than happy to offer solutions in the event of wear problems with rollers; our expert team is on-hand to optimize your processes.

Nonwoven Industry

All embossing roller designs in the nonwoven industry can be created directly on steel using the laser process. At the moment, the only limitation is the current possible cylinder sizes.

Napkin Industry

High-precision designs for steel/steel and steel/paper applications — engineered for consistent quality. The napkin industry is yet another sector that can benefit from gravion's innovative technology. Here, design possibilities and highly accurate embossing structures are of the utmost importance. We are able to manufacture embossing rollers and union set embossings (positive/negative) for this field of industry.

Special Projects

If it’s unique, complex, or needle-based — we support it. Nothing is too special.

Explore Industries | Explore Materials

gravionYour Partner in Precision

At Gravion, we don’t just manufacture embossing tools — we engineer reliability, consistency, and beauty in detail. Our Union Rollers are built to turn precision into performance and ideas into reality.

Contact us today to discuss your steel-to-steel embossing application:
info@gravion.eu | +49 7623 74 790-00 or reach out to our global Gravion sales network.