A Little Known But Critical Relationship

Your Manufacturing Quality Depends On Your Roll Profiles

How much of an impact could your rolls really have? In your eyes, your rolls are just fine. Maybe they have small imperfections, but that won’t have much of an impact on your manufacturing quality, right?

The harsh reality is that this sentiment couldn’t be further from the truth. And it’s costing you big time.

The smallest imperfection in your roll not only affects its shape, but also deeply impacts your manufacturing and product quality, your reputation and your production efficiency and profitability. 

A $110 Billion Flaw  

In 2010, the Federal Reserve began printing new, high-tech $100 bills. A seemingly unnoticeable flaw in the printing press created a production-halting defect on the new bills. This imperfection caused the paper to fold over in production, leaving a portion of the bill blank. Not only was production of the new bills shut down, but more than one billion bills were forced into quarantine.

The value of flawed and unusable bills totaled $110 billion – more than 10% of the global supply of U.S. currency.

Which Flaws Wreck Your Manufacturing Quality?

The three most common roll defects include:

  • Barring
    Identified by cross-machine variations on your rolls, barring often transfers such variation to your products.
  • Feedlines
    Typically characterized by striping or scoring around your rolls, this defect often resembles a barber pole and is also imprinted on your products.
  • Chatter
    Resembling the effects of barring, chatter has a shorter frequency. The negative product effects are similar. 

One of the biggest issues with these defects is that they are not necessarily visible to the naked eye. However, the transitive effects on your products are very detectible – by you and your customers.

These flaws diminish your customers’ manufacturing quality and products, and are a clear sign of imperfection in your production process. The effect of your tarnished reputation could be far reaching. Manufacturers are incredibly dependent on the quality of their products and the subsequent trust that customers have in that quality. Should your quality be questioned within your industry, the impact could be crippling.

If your manufacturing quality is a product of roll defects, it’s time to look at your roll grinding.

Precision Grinding: The Only Solution To Your Problem

Proper roll grinding fixes the imperfections in your rolls, but industry best practices are not used universally. Removing rolls from bearings, utilizing CNC grinding (and, in some cases, 3D grinding) and partnering with a precision grinder are the only ways to ensure that your product quality improves.

CNC is used to control the motions of a machine tool and factors such as the speed of a roll. CNC grinding is used for both cylindrical and profile grinding to ensure extremely precise grinds.

CAD and CAM programs thoroughly automate end-to-end component design, passing information on the exact needs of your roll to a CNC system, which is loaded into the machine for grinding. This highly automated process ensures that your rolls most closely match their original OEM, CAD or CAM design.

Don’t leave your manufacturing quality, efficiency, reputation and – ultimately – profitability to chance. Ensure the perfection of your rolls with precision grinding.

To learn more about how PRG increases your production efficiency and quality with precision roll grinding, contact the experts.