If you’re going to debate the merits of rebuilding your roll grinder versus relying on the expertise of a precision grinding company, it’s best to keep the conversation focused on the expense-related side of things.

This isn’t because operational and production efficiency aren’t important. In fact, they’re extremely important and have a huge impact on your bottom line. It’s because the efficiency comparison between using an in-house roll grinder and outsourcing to a roll grinding expert is like comparing the benefits of using a butter knife versus a steak knife to cut into a juicy filet mignon.

Why?

Your rolls must have a precise profile, roundness, shape, TIR and concentricity in order for your production to achieve maximum efficiency. Whether your rolls need repairs or are brand new, it is extremely difficult for an in-house team to use a roll grinder to grind them to perfection. It’s not that your grinding team isn’t knowledgeable, but they’re using equipment that doesn’t compare to that of an expert precision roll grinding company. In fact, most grinders were designed to grind rolls on the bearings and housings, which results in more roll defects, such as chatter, barring, feedlines and lack of concentricity.

In this aspect, an in-house roll grinder typically cannot compete with an expert’s equipment.

Tallying Up The Expenses

Most manufacturers assume that outsourcing roll grinding is a costly endeavor. Some businesses have a mentality that outsourcing any service is going to be more expensive. But when it comes to roll grinding, there are elements of the total in-house grinding cost that are often overlooked. From the cost of a typical roll grinder to the expenses incurred for electrical, supply, environmental and the labor of a four-man, full-time crew, as well as other overhead, using your own grinder amounts to more than $600,000 annually.

Now, add in the typical cost to rebuild a roll grinder. If your eventual rebuild requires upgraded electronic control components, software and drives or another technology piece, the total expense can be as much as $1 million.

Expert, precision roll grinding not only considerably increases the life of your rolls and covers, but also reduces operational downtime – an exponential cost. The expenses you would have incurred to fix your grinding equipment will no longer cut into your profitability. This is true from the perspective of both repair costs and operational inefficiencies.

While everyone’s situation is unique, a true comparison between the costs of all relevant in-house expenses and the cost of outsourcing to an expert might lead you to make a different decision. With imperfect, worn-out or inadequate equipment, it simply doesn’t make sense to rebuild your roll grinder.