When converters search for carbon fiber air shafts, they’re usually looking for three things: lighter weight, higher speeds, and improved reliability. But not all carbon fiber shafts deliver the same performance.
Carbon fiber is only part of the equation; what sets some shafts apart is how the design translates into real-world performance advantages.
That’s where the Double E Group’s DLB-2000 Carbon Fiber Air Shaft sets itself apart. It’s not only lighter, but smarter by design, combining advanced materials and engineered components to deliver consistent performance where it matters most.
Carbon Fiber vs. Metal Shafts
Double E Group pioneered the use of carbon fiber in shaft housings back in 1986. This evolution in shaft design elevated both safety and efficiency in converting applications, replacing traditional steel shafts with a more than 50% lighter, high-performance alternative.
What that means for converters:
- Turn a two-person lift into a one-person job
- Meet OSHA guidelines and minimize operator risk
- Improve ergonomics and changeover speed
These benefits highlight why Double E Group’s carbon fiber shafts have become a trusted solution for improving safety and efficiency in converting operations.
Not All Carbon Fiber Shafts Perform the Same
While many shafts on the market use carbon fiber tubing, few deliver where it counts most in converting. Real performance comes down to maximizing uptime, maintaining roll quality, and running reliably at higher speeds without compromise.
The DLB-2000 is engineered not only to be lighter than steel shafts, but to meet these performance demands in real converting applications.
1. Superior Strength and Reduced Deflection
By combining premium carbon fiber with a proprietary, in-house, winding process, Double E Group engineers shafts that maximize strength and performance, reducing deflection and ensuring consistent, high-quality roll output.
This translates directly into measurable performance benefits in converting applications:
- Reduced vibration and roll bounce
- More stable web handling at higher speeds
- Improved roll quality
Many competing shafts struggle to deliver this level of consistency, particularly in wider or high-speed operations where deflection and instability become more pronounced.
2. Higher Critical Speeds = More Throughput
The DLB-2000 is designed for higher critical speeds, allowing converters to increase throughput without sacrificing stability. In this way, carbon fiber becomes a true productivity driver rather than simply a weight reduction tool.
With the DLB-2000, overall productivity and operational output are improved through:
- Increased throughput – lines can run faster, produce more
- Supports smoother operation – withstands demanding, continuous-use environments
- Maintains stability at higher speeds – ensures consistent performance during operation
With the DLB-2000, higher critical speeds translate directly into measurable improvements in throughput and consistency. This allows converters to operate more efficiently while maintaining reliable performance across demanding applications.
3. Engineered Protection for Longer Shaft Life
Carbon fiber delivers strength and weight advantages, but long-term performance depends on how well it is protected in real-world applications.
The DLB-2000 is designed with premium-grade metal shaft sleeves, using aircraft-grade aluminum for lightweight performance or high-grade steel for enhanced deflection control and wear resistance. Each sleeve is precision machined and finished to ensure durability and consistent performance over time.
By protecting the carbon fiber from abrasion, this engineered sleeving plays a critical role in helping to extend shaft life and maintain performance in demanding, continuous-use environments.
With the DLB-2000, this translates into:
- Extended shaft life – carbon fiber is protected from abrasion and wear
- Application-specific performance – sleeve material options based on operational demands
- Improved durability – long-term use possible in demanding converting environments
The result is a shaft built to last, unlocking its full value by ensuring both performance and longevity over time.
4. A More Reliable Approach to Bladder Design
The bladder is one of the most failure-prone components in any air shaft. The DLB-2000 uses a proprietary polyprene bladder that resists punctures, heat, and abrasion. It is designed to consistently retain its shape, even under the demands of repeated use. This also ensures consistent lug collapse for easy core removal.
Why this matters:
- Fewer unexpected failures
- Consistent performance over time
- Reduced maintenance headaches
Additionally, with the use of quick-change pneumatic inserts and pre-cut bladder cartridges, shaft maintenance is quick, easy and greatly reduces downtime.
5. Springless Lug Design for Better Grip and Less Downtime
The DLB-2000 replaces traditional spring-based lugs with a springless design, eliminating components that can break or compromise bladder integrity. By eliminating a common failure point in traditional lug designs, it supports longer bladder life and more reliable performance over time.
Double E Group shaft lugs also feature:
- Diamond plate gripping surfaces – better grip with less slipping
- Larger surface area contact – transmits maximum torque for positive shaft to core gripping
- No internal springs to break
The DLB-2000 provides a more reliable and efficient approach to core gripping. In addition, Double E Group offers a range of options to accommodate different core materials and application requirements.
6. Designed for Fast Maintenance and Minimal Downtime
In converting operations, downtime directly impacts productivity, making ease of maintenance a critical factor in shaft design. The DLB-2000 is engineered to simplify servicing and reduce time spent on maintenance. With user-focused design features and accessible components, routine upkeep can be performed quickly and efficiently, helping keep lines running.
Key maintenance advantages allowing for faster servicing, reduced downtime, and easier overall maintenance include:
- User-removable journals
- Quick-change bladder systems
- Streamlined component access
This design approach helps keep the shaft operational longer while minimizing interruptions to production, resulting in faster maintenance, reduced line stoppages, and a lower total cost of ownership.
The Double E Group Difference: Engineered for Converting Performance
The real advantage of the DLB-2000 comes from how each component is engineered to work together. While many suppliers offer carbon fiber shafts as a material upgrade, Double E Group focuses on overall shaft design, ensuring that the carbon fiber tube, lugs, and bladder are all built for reliability in demanding converting environments. This results in safer handling due to reduced weight, higher critical speeds for increased throughput, longer shaft life through protective sleeving, improved core gripping, and easier maintenance.
Ultimately, the decision is not just about carbon fiber versus steel, but about choosing a shaft designed for real-world performance. The DLB-2000 reflects years of engineering experience and design, delivering the durability, safety, and efficiency converters depend on every day. Contact us today to get more information about adding the DLB-2000 to your converting production.