How To Eliminate Barring And Achieve Tighter Tolerances

Aiming For Ultimate Precision In Your Production Line With PRG

Most manufacturers that deal with calender rolls also dealt with roll barring. When you have barring in your rolls, this issue leads to inconsistent products and often results in higher waste, downtime and costs for your production process, and also, results in similar issues for your customers.

When you eliminate barring, you get more consistency and less waste from your production line. Continue reading for an explanation on the science behind barring, the benefits of barring prevention and the best way to eliminate barring from your production line -- plus, a video that sums it all up!

What exactly is barring?

Calender barring is a harmonic roll surface problem that affects the longevity of calender rolls and product quality, thus leading to excessive machine excessive downtime.

What are the key benefits of barring prevention?

  1. Reduce grinding frequency.
    The “corrugation” that results from roll barring extends and expands even the smallest inconsistency across the surface of your rolls. Keeping your rolls in spec and free of barring, results in less frequent grinding and a more consistent product.
  2. Cut down on waste.
    An amazing number of rolls are ground and finished with residual barring which is very difficult to see with the naked eye. Installation of these barred rolls requires considerable fine-tuning throughout their shortened life. When you eradicate roll barring from the process, you reduce this waste and make for a more efficient production line.
  3. Get easier caliper control and tensile strength.
    Roll barring elimination enhances the machine direction profile of the product during the manufacturing process, allowing for uniform printing, tensile strength and production efficiency.

How do I eliminate barring?

Traditional grinding methods are inconsistent and don’t work. For example, grinding rolls on bearings is a common practice to clean up rolls and try to reestablish the original specifications. However, this is not effective.

Bearing and housing removal must be implemented first. The bearing seats and the roll faces must be ground round and concentric.

For an unbiased appraisal of the condition of your bearings and housings, leave the removal process to the experts. Then, once the removal of bearings and housings is completed, the bearing seat is ground round and concentric to the roll face. This means less maintenance, less machine downtime and most importantly, more consistent production.

Roll barring presents a major obstacle to both consistency and quality control, which are key considerations for every industry, from the manufacturing floor to the front office.

Click the button below to watch a short, informative video on how to prevent barring and achieve tighter tolerances from your production line.
» Watch Now

To learn more about how Precision Roll Grinders performs comprehensive roll grinding services for a variety of industries, visit PRG online..

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"PRG is an excellent strategic partner with their experienced and professional people. We know we can depend on PRG for high quality work and excellent service. Such a high comfort level is valuable to us."
-- David A. Robinson, Area Maintenance Supervisor -- Paper Mill, Wickliffe Paper Mill, NewPage Corporation
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Featured Case Study:

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 -

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