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In any production environment, your main objective is to keep costs down and production efficiency up. This is especially true in the food industry, where you’re generating a large amount of raw materials every day.

If you’re a production manager in the food industry, there are often three major challenges you must overcome: lost yield, mounting energy costs and a lack of proper internal roll care. Find out how you’re able to solve these problems with proactive roll maintenance.

When you come down with a cold, you’re usually saddled with issues like coughing, sneezing and running a fever. Symptoms like these tell you that something is amiss with your health. That’s how you know it’s time to call the doctor for an appointment and some medicine.

When your rolls are in need of maintenance, they show symptoms, too. That’s when you should be alerted that it's time to call your roll maintenance provider for an appointment and some general repairs.

In this article, we’ll explain how to tell when you need to consult a roll maintenance provider to improve roll performance. Explore these five clues that your rolls are in need of maintenance to increase production efficiency.

Whether you’re in paper, plastics, rubber, food, nonwoven materials or some other industry, the goal for your company is simple: Bring in more profits than you spend on costs. Usually, that’s easier said than done – especially when it comes to production. Your profits are often diminished by unexpected downtime, decreased production efficiency, lowered yield and unforeseen maintenance costs.

So, how can you cut your expenses to generate an increase in profits? It all starts with regular and proactive roll maintenance. Your rolls are at the heart of your manufacturing operation. When they’re properly cared for, you’re able to achieve a major boost in production efficiency.

Here are five secrets from a roll maintenance expert on why roll grinding is the key to increasing profits.

Your operations need precise roll grinding in order to maintain production efficiency. But, it’s important to know that this is a process requiring the attention of roll maintenance experts.

When you hand your rolls over to expert roll grinding providers, a comprehensive maintenance routine begins. It ends with rolls that are precisely ground to your specifications based on your production requirements.

Addressing needs from roll grinding to total roll rebuilds, experts have the capability to achieve unmatched precision. Watch our video now to explore the roll maintenance process and how your rolls could be returned to near-perfect roundness.

In the paper industry, manufacturing precision is essential to generating a high-quality product. You want to manufacture flawless paper that your customers are able to rely on.

If you’re using calender rolls in your paper manufacturing process, you’ve likely faced barring – diminishing the quality of your paper and killing your profitability.

Barring is a roll surface problem: peaks and valleys in your roll that prevent it from turning smoothly. It’s the enemy of many paper manufacturers, as it causes inconsistencies in paper quality. You may notice unevenness in thicknesses, paper strength or glossiness.

If your paper displays any of these inconsistencies, it’s not meeting your standards or those of your clients. It could even cost you business.

For any industry, compliance is an important topic. Whether it’s to abide by safety regulations or production standards, many companies invest a lot of time and money into keeping their operations up to code.

In the ink industry, ANSI standards carry a lot of weight. The American National Standards Institutesupports and facilitates the voluntary consensus standards for the nation’s products, services, processes and systems. And, with the help of the National Association Of Printing Ink Manufacturers, ANSI has developed safety requirements that may compel you to invest in roll maintenance in order to meet their standards. 

An issue that many commercial roll users face is barring: peaks and valleys in the rolls that prevent you from providing the best possible manufacturing product. Barring is often hard to detect on a recently serviced roll – and even harder to eliminate – unless you’re working with a precisionroll grinding expert.

Most rollmaintenanceproviders make the mistake of grinding the roll while it’s still on the bearings, a technique that fails to eliminate barring issues. Instead, you should be working with a roll maintenance expert who removes the housings and bearings before each grind, as this enables them to achieve the tightest tolerances.

When roll grinding is approached this way, you get the most defect-free, roundest rolls – which affects your production quality, efficiency and profitability in a positive way.

Imagine getting to work and realizing that your computer or laptop is broken. What would you do all day? You could go home and use the computer there, but you’d be losing time in the drive. You could call your IT services provider to fix the issue, but that takes time – and they might not be able to repair it today.

When the technology you rely on becomes unreliable, you lose an immense amount of time, energy and productivity in getting your operations up and running again. The same is true when it comes to your manufacturing rolls.

Whether you manufacture paper, plastic, rubber, food or any product that depends on rolls, you want to be confident that your operations won’t be stalled by failing rolls with uneven profiles/surfaces.

Of course, no manufacturing operation can claim zero downtime. It’s inevitable at some point, regardless of the time and effort you put into eliminating it. But, you’re able to minimize manufacturing downtimeas much as possible when you apply a proactive approach to rollmaintenance.

When your car is having trouble, you want to find a mechanic with the best technology to diagnose and repair your vehicle. They should definitely be familiar with the high-tech, modern computers that run cars, and have the appropriate tools to handle your repairs.

From your car to your computer and everything in between, technology – and the know-how to utilize it properly – is a big factor in deciding whom you trust your maintenance needs to.

This technology and expertise is imperative with your rolls, too. Your rollmaintenanceprovider should be able to grind your rolls to your exact specifications. That’s why you need an expert who knows how to employ CNC grinding.