A LOT OF money.

When a kraft paper facility was seeing a lot of scrapped product due to poor calender roll profile, it wisely turned to PRG for a solution. We delivered. And then some.

Unlike the previous roll service provider, we grinded both rolls in the calender on their journals. And the difference was immediately noticeable. Yes, the quality of product improved and the amount of scrapped product dropped drastically. The customer was delighted. But the best was yet to come.

Prior to the PRG regrinds, the stack life for these rolls had been just six months. But as the paper facility would soon discover in the next calender cycle, the PRG-ground rolls were expected to extend the life of their stack to 24 months — four times past their previous roll life. (A recent analysis on the calender stack shows that the current rolls could even last well over 36 months.)


After installation, we tracked the facility’s data pertaining to caliper to validate the true value our rolls delivered. The results we obtained proved that our rolls were able to help the paper producer create a better product. And for a longer period of time.

Servicing your calender rolls every two years instead of every six months, as in the case of this customer, could lead to a savings of $100,000 — and the reduction of variation in your process could be worth 10x as much. Properly serviced rolls are the key to cutting production costs and providing savings. Savings you might not have even been anticipating.