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Precision Roll Grinders vs. Other Grinding Services: The Rewards of Value, Part 2

Posted by Doug Thompson on Jul 26, 2018 9:15:00 AM

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!

 

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Topics: Best Practices, Roll Grinding, Maintenance, Process Improvements, Manufacturing Profit

Precision Roll Grinders vs. Other Grinding Services: The Rewards of Value, Part I

Posted by Doug Thompson on Jul 17, 2018 11:00:00 AM

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.

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Topics: Best Practices, Roll Grinding, Maintenance, Process Improvements, Manufacturing Profit

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: Best Practices, Roll Grinding, Maintenance, Process Improvements

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: Rubber Industry, Process Improvements

4 Profitable Reasons to Improve Your Specialty Coatings Process

Posted by Robert Rourke on Jun 20, 2017 10:00:00 AM

Manufacturers of specialty-coated products have unique challenges, costs, or risks because of the additional processes and materials involved.

That’s why correct roll geometry is critical to creating consistent, accurate coatings. Whether you’re running a gap nip or a contact nip, roll geometry affects material usage, coating thickness consistency, and process speed — just to name a few key metrics.

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Topics: Film Industry, Process Improvements, Best Practices

3 Warning Signs of Press Section Roll Problems

Posted by Robert Rourke on Mar 1, 2017 10:59:53 AM

Reduce costly inefficiencies and extend the life of your rolls 

Machine downtime is not the only threat to your mill’s bottom line. During the life of a press section roll, inefficiencies that seem minor can accumulate expenses beyond the cost of a grind or repair.

Here are 3 warning signs that you may have a press roll problem:

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Topics: Paper Industry, Process Improvements

Why Papermakers Win When They Truly Follow W. Edwards Deming

Posted by Robert Rourke on Jan 30, 2017 8:00:00 AM

Edwards Deming, American management consultant, had a lot to say about quality in manufacturing processes.

His insights revolutionized quality standards all over the world. In his 14 Points for Management, he noted that management’s job was to ensure people and machines consistently improve.

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Topics: Paper Industry, Process Improvements, Best Practices

How To Slash Your Manufacturing Downtime With Proactivity

Posted by Robert Rourke on Dec 29, 2015 10:30:00 AM

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.

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Topics: Roll Grinding, Maintenance, Process Improvements

4 Ways To Extend Roll Life And Boost Production Efficiency

Posted by Robert Rourke on Nov 11, 2015 10:30:00 AM

When you run your production machines each day, you rely on them to operate smoothly and generate products that meet your specifications. But, what happens when this equipment fails?

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Topics: Roll Grinding, Maintenance, Process Improvements

The Real Cost Of Using Worn Rolls In Chocolate Manufacturing

Posted by Richard Reph on Oct 23, 2015 11:59:48 AM

You’ve heard about the many ways in which worn rolls impact your chocolate process.

You end up with a gritty, out of specification, product that isn’t usable.
You slow production with unexpected downtime.
You’re unable to achieve maximum levels of efficiency.

But, do you know how many dollars you’re actually losing when you fail to protect the quality of your rolls? Here’s your opportunity to see the math behind it all.

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Topics: Roll Grinding, Chocolate Industry, Process Improvements

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