Poor caliper control wreaks havoc on production control and product quality. Uneven thickness leads to print defects, sheet breaks, and frustrated customers rejecting orders. Maintaining tight control is essential to ensuring consistent product performance.

A Southern linerboard papermill had onging product quallity issues. Working jointly with PRG, a calender stack was precision ground and placed in production. Data was analyzed over an 8 week period to determine the impact of precision ground rolls on the process. The resulting study showed improved caliper control without sacrificing strength characteristics.

Upon installation, the facility immediately saw a 70% reduction in 2Sigma caliper variation, leading to significantly improved caliper profile control. This enhanced stability not only optimized sheet uniformity but also allowed the facility to reduce calender stack loading, minimizing wear on equipment. After achieving this new level of caliper control, the mill was able to reduce fiber costs by running the caliper closer to the minimum specification, generating over $2000 per day in fiber savings.