Case Studies

Delivering “Well-Rounded” Solutions

The Problem - Flanders has the capability to handle their own grinding and maintenance in-house, but when demand for servicing their large-sized motor armatures increased rapidly, they needed a reliable backup service provider.
PRG's Solution - Read More...


Twin Rivers Paper Company.

The Problem - Twin Rivers Paper Company was having considerable hazing problems and build-up on their number 3 paper machine's hot calender roll. As a result, they were routinely spending more than 6 hours per month cleaning the roll before changing paper grades.
PRG's Solution - Watch here...


Alsco Metals, Inc.

The Problem - A variation in Alsco’s process reduced plant efficiency — and increased day-to-day operational costs.
PRG's Solution - Read more...


Blue Ridge Paper Products, Inc.

The Problem - Blue Ridge faced troubles after a bad grinding experience with another supplier. As a result, production didn’t meet Blue Ridge’s standards of quality.
PRG's Solution - Read more...


Boise Papers

The Problem - Prior to working with PRG, Boise was required to change its #2 paper machine calender rolls every two months due to extreme wear. This caused excessive machine downtime — which ultimately affected Boise's bottom line.
PRG's Solution - Read more...


JSW Steel

The Problem - When the grinder or lathe goes down, Jindal United Steel Corporation, a division of JSW, must act quickly to avoid excessive downtime in the production area. Prior to engaging PRG, the mill was forced to use a distant supplier who provided a service that barely met mill standards – causing production delays and occasionally even the need to stop the production process.
PRG's Solution - Read more...


Kellogg's

The Problem - For several years, Kellogg's has commissioned PRG to grind a variety of rolls. Over the July 4th holiday, the Lancaster plant faced a unique emergency. An anvil roll was producing inconsistent sheets which put the process equipment at risk of severe damage and, subsequently, produced an inferior product. Internal engineers suspected that the roll was out-of-round, but they had no concrete proof. Additionally, the plant did not have any drawings for this one-of-a-kind roll, making matters more complicated for determining a clear solution.
PRG's Solution - Read more...


Lone Star Steel Company

The Problem - When the lone roll grinder at Lone Star Steel Company went down unexpectedly, there was really only one choice: call PRG. Fortunately, with a PRG facility just across the Arkansas border in Texarkana, that call was little more than a holler.
PRG's Solution - Read more...


NewPage Corporation

The Problem - For many years, NewPage’s Wickliffe, KY mill used different suppliers for roll repair and grinding services. The lack of consistency produced mixed results.
PRG's Solution - Read more...


NGC Industries

The Problem - Heavily used calender and wire return rolls showed wear bands shortly after regrinding — costing NGC a substantial amount of money in repeated regrinds, downtime and product quality. Two years ago, when Production Manager Robert Hickox discovered that NGC’s supplier was outsourcing his rolls, he decided to work directly with PRG.
PRG's Solution - Read more...


Steel and Pipe Company

The Problem - Steel and Pipe Supply Company has an excellent reputation for on-time delivery. Its multiple facilities, as well as unmatched size and vast inventory, often attract the largest and most demanding customers. In order to supply this demand, Steel and Pipe depends on its temper mill rolls to run effectively and efficiently – every roll must be ground to the tightest tolerances to yield the best quality products.
PRG's Solution - Read more...


Wausau Coated Products

The Problem - Wausau’s rolls require extremely tight tolerances to withstand elevated temperatures of 350° Fahrenheit. Under these conditions, the typical roll requires replacement after only six months. As a result, excessive downtime affected the mill’s productivity and profitability.
PRG's Solution - Read more...


White Birch Paper Bear Island Division

The Problem - One year ago, Bear Island Paper faced an internal emergency. In order to avoid a total shut-down, the mill needed six rolls serviced within a couple of weeks.
PRG's Solution - Read more...


UPM Blandin

The Problem - In 1989, Blandin started up their #6 paper machine line with two modern super calenders. Over time, barring created a wear pattern, leaving an impression on the finished sheets. At one point, the mill had to change chilled iron rolls every six weeks. The resulting downtime greatly affected productivity.
PRG's Solution - Read more...

TESTIMONIALS

"PRG delivers fast, is very professional and easy to work with. In one instance, PRG's final cost came in $5,000 less than quoted. And, PRG always follows up by email or a personal visit."
-- Tom Peters, Maintenance Manager, O'Sullivan Films
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Featured Case Study:

Boise Papers
The Problem - Prior to working with PRG, Boise was required to change its #2 paper machine calender rolls every two months due to extreme wear. This caused excessive machine downtime — which ultimately affected Boise's bottom line.
PRG's Solution - Read More...

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