At Cottam Brush, innovation has always come from listening closely to engineering challenges in the field. One recurring issue we hear from OEMs and engineers is the difficulty of manufacturing large, precise roller brushes, particularly where shaft size, geometry, or application demands push beyond the limits of conventional brush construction methods.
That challenge led to the development of BrushWrap: a new brush-making concept designed to create accurate, consistent brush surfaces on large shaft-mounted rollers, while opening up new possibilities in brush design.
Rethinking How Roller Brushes Are Made
Traditional roller brushes are typically produced using punched, spiral-wound, or segment-based construction methods. While these approaches are proven and effective, they can introduce limitations when rollers become larger, longer, or more complex in shape.
Brush Wrap takes a different approach.
Instead of manufacturing the brush directly in its final curved form, the brush is first produced as a flat, linear structure. It is then formed into smooth, continuous curves using specialised formers, allowing it to wrap precisely around a shaft or roller body.
This method is inspired by kerf cutting, a technique used in joinery and furniture making where solid materials are carefully cut to allow them to bend into elegant, flowing shapes. By applying this principle to brush stock, we are able to achieve the same transformation, turning flat brush sections into robust, functional, curved brush surfaces.
Designed for Large Shaft & Roller Applications
Brush Wrap was developed specifically with large roller brushes in mind. As roller diameters increase, traditional manufacturing methods can become more restrictive, both in terms of geometry and consistency.
Because Brush Wrap is formed after manufacture, it allows for:
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Greater flexibility in roller diameter and length
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Accurate conformity to the shaft surface
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Consistent brush density across the full working width
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Improved control over brush geometry
This makes it particularly well suited to shaft-mounted rollers where precision, durability, and repeatability are critical.
A Brush-Making Method, Not an Industry-Specific Product
While Brush Wrap was designed with demanding applications in mind, such as recycling systems and conveyor belt cleaning, it is not limited to any single industry.
Instead, Brush Wrap is best described as a manufacturing method rather than a fixed product.
Any industry that uses roller brushes on shafts may benefit from this approach, including:
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Material handling and conveying
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Recycling and waste processing
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Cleaning and separation systems
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Surface conditioning and preparation
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Industrial transport and processing lines
Wherever a large roller brush is required, Brush Wrap provides engineers with an alternative way to think about design, manufacture, and integration.
Engineering Benefits of the Brush Wrap Concept
From an engineering perspective, Brush Wrap offers several practical advantages:
Design Freedom
Producing the brush flat first allows for greater control over brush layout before forming, enabling more complex or application-specific designs.
Consistency at Scale
Maintaining uniform brush density and filament presentation becomes increasingly important as roller size grows. Brush Wrap helps deliver consistency across the entire brush surface.
Improved Fit & Conformity
The wrapped design allows the brush to follow the shaft accurately, reducing tolerance issues and improving overall performance.
Potential Manufacturing Efficiencies
By removing some of the constraints associated with large-diameter brush construction, Brush Wrap opens the door to more efficient production routes for certain applications.
Developed In-House by Cottam Brush
Brush Wrap is a Cottam Brush concept, developed in-house by applying established manufacturing principles in a new way. As with all our brush solutions, it can be:
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Engineered to suit specific shaft sizes and operating conditions
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Manufactured for bespoke OEM requirements
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Adapted for different filament types and duties
Whether the requirement is aggressive cleaning, controlled contact, or long service life, the Brush Wrap method can be tailored to meet the demands of the application.
Opening New Possibilities for Roller Brush Design
Brush Wrap is not intended to replace traditional roller brush manufacturing methods. Instead, it adds a new option to the engineer’s toolkit, particularly for applications where size, geometry, or consistency present a challenge.
By rethinking how brushes are formed, Brush Wrap allows for:
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Larger roller brush designs
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More controlled brush surfaces
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Greater flexibility during the design phase
It represents a practical step forward in how roller brushes can be manufactured and applied.
Find Out More
If you are an engineer or OEM working with shaft-mounted roller brushes and would like to explore whether the Brush Wrap concept could benefit your application, we’d be happy to discuss it with you.
Contact our team at
sales@cottambrush.com
to find out more or to talk through your requirements.