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In Part 1 of our series, we discussed PRG’s value in terms of roll longevity (roll shape over time). This week, we’ll attach the dollar amounts associated with working with PRG vs. working with roll grinding services with lower UPFRONT costs. We’ll also discuss the HIDDEN costs that, at the end of the day, gouge your bottom line – by thousands of dollars!

A True Story

Here’s a true story to demonstrate cost savings. A maintenance supervisor chose the least expensive roll grinding service from a short stack of bids. Upper management was pleased, but only for a little while. Within 6 months, the roll caused chaos in the production line, producing chatter, barring, profile variations and unplanned maintenance. The roll was sent for another roll grind.

Over the years, PRG has reground many rolls originally ground either in-house or by other companies. The story is familiar. That roll was likely ground improperly for one of the following reasons:

• It was ground on bearings and housings left fixed to the roll.
• The work was not performed in a temperature-controlled environment.
• The roll wasn’t set up with the crown positioned properly.

Reel spools are the most highly stressed rolls in your paper mill. Large loads on heavy spools take their toll. After time, bent journals can easily break. Those breaks put not only your equipment, but also your employees at risk.

Pre-impregnated (prepreg) materials create strong, lightweight composite materials which are used for aerospace, construction, transportation and medical applications – all industries that rely on precision. A uniform and consistent prepreg matrix film is the key to product efficacy. Film consistency is directly related to roll geometry. Roll geometry includes the TIR, Roundness and Profile tolerances.

The paper industry is changing. McKinsey & Company reports, “Packaging is growing all over the world, along with tissue papers, and pulp for hygiene products. Although a relatively small market as yet, pulp for textile applications is growing. And a broad search for new applications and uses for wood and its components is taking place in numerous labs and development centers.”

To meet the demand of the changing market, mills need to produce more high quality product. They must find ways to produce faster while maintaining high quality and reducing downtime to keep up with demand for packaging grades, coated board, tissue, newsprint, office paper, and more.

The adage, “Work smarter, not harder” applies to all of us. If a simple improvement can save you time, money and resources, it’s well worth the initial investment.

A large paper manufacturer in the Northeast experienced hazing issues on their coated hot calender rolls. Every time they ran a critical grade of paper with a demanding finish, the hazing decreased the quality of the product.

Every square inch of a 33,000-pound roll needs to perform perfectly. After a time, all rolls need maintenance. At this moment, a user has a choice of roll grinding services. Choose wisely!

Wet Streaks Have Caused the Paper Industry Problems for a Long Time

A 1921 Edition of The Paper Mill and Wood Pulp News reported, “Previous to the installation of suction couch and press rolls, paper carried unequal amounts of water to the dryers. Spots and wet streaks prevailed.”

Everyone in the Paper Industry Has Struggled with Wet Streaks.

Some believe that wet streaks are just part of a machine’s profile. Others have tried everything, including adding unnecessary technology. These expensive adjustments include:

Certain components are built to withstand the rigors of large scale manufacturing. For those who work in or around lime kilns, cement plants, paper mills or other heavy-duty industrial processes, some parts of your line may seem nearly invincible.

Operations Managers and Maintenance Supervisors often take these components for granted – simply because they almost never require repair.

Take Trunnions For Example.