Value in Quality Grinds:
The profile of rolls in a rubber calendering process have a direct impact on variation in the product. A rubber calendering facility was experiencing problems with product variation. Adjustments on the machine were not helping the quality of the product and many of the settings were being maxed out. The customer agreed to have one calender stack ground by PRG as a proof of concept. The profile was vastly improved with just one stack being precision ground. The results were so immediate that the customer decided to have their second calender stack ground by PRG.

Let the Data Do the Talking:
The 2 images represent the roll profile variation and product variation before after both of the calender stacks were ground. The product improvement, clearly seen in cross direction variation, was improved by over 25%! Additionally, the direct effect the roll's profile has on the product profile can clearly be seen in this trend. The high ends were significantly reduced and the remainder can be attributed to the current crown on the rolls. As a result of the improved profile, the target spec can be moved closer to the lower spec resulting in material savings exceeding $100,000’s!