Precision roll profiles are crucial when it comes to maintaining good caliper control. High caliper variation can cause poor product quality, increased rejects, sheet breaks and excessive fiber usage. Maintaining tight caliper control is essential to keeping operations running smoothly and ensuring consistent product performance.

A recent case study demonstrated the real-world impact of precision roll grinds on product quality and operational efficiency. A coated board mill was looking for opportunities to make the machine more efficient and to reduce fiber usage. The mill decided to partner with Precision Roll Grinders to grind a full set of dry and wet stack calender rolls. This immediately resulted in a significant and lasting reduction in the cross-directional caliper variation.

The precision ground rolls produced over a 30% reduction in 2-sigma CD Caliper Variation. The enhanced stability not only optimized sheet uniformity but also allowed the facility to reduce calender stack loading and reduce variation in the basis weight. These improvements allowed for a reduction in fiber, with annual savings of over $400k.

Contact PRG today to be connected with your region’s Account Manager.