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Robert Rourke

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Why It Takes 24 Points to Prove Your Rolls are Round

Posted by Robert Rourke on Mar 13, 2018 11:00:00 AM

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.
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Topics: Roll Grinding, Best Practices, Maintenance, Process Improvements

Real Help with Reel Spool Maintenance

Posted by Robert Rourke on Feb 22, 2018 11:45:00 AM

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.

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Topics: Paper Industry, Roll Grinding, Safety, Best Practices, Maintenance

Superior Prepreg Manufacturing: It’s all about Tight Tolerances

Posted by Robert Rourke on Feb 13, 2018 11:15:00 AM

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.

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Topics: Roll Grinding, Best Practices, Nonwovens Industry, Maintenance

Roll Armor® Ceramic Coatings Protect Your Rolls, Your Product and Your Bottom Line

Posted by Robert Rourke on Jan 30, 2018 11:00:00 AM

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.

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Topics: Paper Industry, Roll Grinding, Best Practices, Maintenance

Roll Armor Coating Eliminates Major Maintenance Headache for a Paper Mill

Posted by Robert Rourke on Nov 2, 2017 10:00:00 AM

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.

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Topics: Paper Industry, Roll Grinding, Best Practices, Maintenance

Not All Roll Grinding Services Perform Equally: A Case Study for The Nonwovens Industry

Posted by Robert Rourke on Sep 19, 2017 11:01:37 AM

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!

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Topics: Roll Grinding, Best Practices, Nonwovens Industry

When Wet Streaks Return, Reevaluate Your Rolls!

Posted by Robert Rourke on Aug 24, 2017 10:30:00 AM

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:

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Topics: Paper Industry, Roll Grinding, Best Practices

Protect Your Trunnion Assembly Investment

Posted by Robert Rourke on Jul 25, 2017 10:01:35 AM

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.

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Topics: Maintenance

Before an Emergency Roll Repair: Your Most Important Choice

Posted by Robert Rourke on Jul 18, 2017 10:00:00 AM

Despite your best efforts, no operations manager or maintenance supervisor can prevent every roll-related emergency that could happen. The challenge is to be ready before (not when) one happens.

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Topics: Roll Grinding, Food Processing Industry, Maintenance

Save $1M in Yearly Tire Production

Posted by Robert Rourke on Jun 27, 2017 9:00:00 AM

If you could save a million dollars by changing one facet of your tire production process, would you?

For product quality and safety, tires require rubber at a specific thickness. If rolls aren’t ground to the exact tolerances needed to achieve that sweet spot, or minimum thickness:

  • You’re using more material than necessary.
  • You’re losing money!
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Topics: Process Improvements, Rubber Industry

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