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Reducing Calender Loading for Lasting Mill Savings
Published on October 7, 2025
A Southern papermill was struggling with excessive calender load and crown pressure, leading to reduced bearing life, frequent roll grinds and exessive hydraulic power consumption.
PRG partnered with the mill and provided top and bottom calender rolls with tight, precision ground tolerances. The mill and PRG collected and analyzed data for over a year, encompassing two different roll cycles.
The analysis showed many quality implovements to the final linerboard product and a nearly complete reduction in calender loading pressure and a 40% reduction in hydraulic crown pressure.
· Bearing life extended (8–10x)
· Longer roll-cover and grind intervals
· Reduced hydraulic power consumption
· Lower stress on journals, housings, and drives
By reducing calender and crown pressures so dramatically, the mill not only improved sheet quality but also unlocked long-term operational savings. Lower loads can translate into fewer unplanned outages, less frequent roll servicing, and measurable energy reductions. PRG roll grinds give the mill confidence that its assets will run longer and more consistently, lowering total cost of ownership. These results show how precision grinding delivers both immediate improvements and durable, compounding benefits.
PRG partnered with the mill and provided top and bottom calender rolls with tight, precision ground tolerances. The mill and PRG collected and analyzed data for over a year, encompassing two different roll cycles.
The analysis showed many quality implovements to the final linerboard product and a nearly complete reduction in calender loading pressure and a 40% reduction in hydraulic crown pressure.
· Bearing life extended (8–10x)
· Longer roll-cover and grind intervals
· Reduced hydraulic power consumption
· Lower stress on journals, housings, and drives
By reducing calender and crown pressures so dramatically, the mill not only improved sheet quality but also unlocked long-term operational savings. Lower loads can translate into fewer unplanned outages, less frequent roll servicing, and measurable energy reductions. PRG roll grinds give the mill confidence that its assets will run longer and more consistently, lowering total cost of ownership. These results show how precision grinding delivers both immediate improvements and durable, compounding benefits.