How To Eliminate Barring And Achieve Better Paper Quality

Aiming For Ultimate Precision In Your Paper Production With PRG

Most manufacturers who deal with calender rolls have also, unfortunately, encountered roll barring.

Roll barring leads to inconsistent paper quality -- variations in paper thickness, glossiness, strength, etc. This downgrade in quality leads to higher waste, downtime and costs for your production process. And as you can imagine, similar detrimental issues are heaped onto your customers.

When you eliminate barring, you get more consistency and less waste from your paper production line. Continue reading for 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 downtime.

What are the key benefits of barring prevention?

  1. Reduce grinding frequency.
    The "chatter" 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, therefore, requires more frequent grinding. So when you reduce barring, you cut grinding frequency.
  2. Cut down on waste.
    An incredible number of rolls are ground and finished with residual barring, but go unnoticed because it's very difficult to see with the naked eye. Installation of these barred rolls requires considerable fine-tuning. 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.
    Roll barring elimination enhances the cross direction (CD) and machine direction (MD) profiles of the product during the manufacturing process, allowing for uniform printing 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 far from effective.

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

To prevent damage to the bearings and housings, leave the removal process to the experts. When removal of bearings and housings is performed effectively, you get tighter tolerances when you grind your rolls. 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 the paper industry.

Click here to watch a short, informative video on how to prevent barring and achieve tighter tolerances from your paper production line.

To learn more about how Precision Roll Grinders performs comprehensive roll grinding services for the paper industry, and achieves tolerances of 20 millionths of an inch, 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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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.
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