No matter the industry, if your production line utilizes manufacturing rolls, even the smallest imperfections lead to flaws in your final product.
When this happens, not only does the quality of your product take a hit, but there’s also a substantial impact on your production efficiency. Together, these effects destroy your bottom line and ruin your reputation.
Barring and chatter are two of the more common roll defects. They are prevalent with rolls in working positions within machine elements, such as nipped rolls in the press section, size presses, calender stacks and offline calenders. The increased mechanical vibration created by barring leads to material fatigue and damages.
Such issues eventually require repairs and expert roll grinding. In addition to the expense of these services, the opportunity cost of production-line downtime is significant – as great as $25,000 or more per hour. This means that two days worth of repairs incurs a cost of $1.2 million.
Roll defects have a greater financial impact beyond the cost of roll grinding and other repairs: They have an enormous effect on your production efficiency and quality.
Roll barring affects paper manufacturers specifically, as this defect is commonly identified by gloss or opacity variations in your sheet. These product inconsistencies reduce the printability of your product. Barred rolls also require considerable fine-tuning and adjustment, which creates waste. With so much waste, your production efficiency suffers.
Another common defect is feedlines, which are characterized by striping or scoring around your rolls. They reduce the tensile strength of finished sheets of lightweight paper grades. The non-uniform concentricity of your rolls diminishes not only the quality of your product, but also that of your customers. In time, the cost of poor quality cuts into your profitability – big time.
If your product is low quality, your customers’ product follows suit. Like you, your customers can’t afford to ruin their reputation by selling anything less than high-quality products. If they notice a pattern of inconsistent or diminished output that affects their ability to produce quality end products, your reputation is going to be tarnished and you may lose your customers.
Traditional roll grinding methods are inconsistent and don’t work. Grinding rolls on bearings, for example, is a common practice that often makes problems worse, not better. Precision CNC grinding, on the other hand, is a best practice.
Proprietary grinding techniques along with the modern CNC systems, computer-aided design (CAD) and computer-aided manufacturing (CAM) programs thoroughly automate end-to-end component design. The CAD and CAM programs produce a computer file, which a post processor reads to identify the commands needed to operate a machine tool. This information is then passed to a CNC system and loaded into the machine for production.
This type of roll grinding process is highly automated and ensures that a roll closely matches its original CAD or OEM design. With such perfection, you reduce the risk of downtime and its associated costs. You’re also able to maximize production efficiency and afford your customers a high-quality product that they can rely on.
To learn more about how PRG increases your production efficiency and quality with precision roll grinding, contact the experts.