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Saving paper manufacturers money one roll at a time. (In this case, literally.)
Published on January 21, 2021
A paper manufacturer recently found out the hard way how poorly ground rolls can bring a production line to an unexpected halt. But in the process, it also discovered the significant improvement that PRG rolls (actually just one roll) can make to a production line.
The manufacturer was running a large fine paper machine with a two-roll calender stack. The rolls had been running for only four months before corrugation issues were noticed. Further inspection showed barring and feedlines in the calender roll face. The rolls might have only been in production for a few months, but they needed servicing again. Right away. Even if it meant incurring an unplanned and expensive downtime, something had to be done and done right away. The paper coming off the machine was unsellable.
In need of an expedited grind, the company reached out to us to service the top roll. We were able to receive the roll, grind it, and return it within seven days. Once installed, the PRG roll made an immediately noticeable difference to the production line and the quality of paper coming off of it. Machine operators reported that the rolls were running better than ever had before. And most importantly, the past issues that the mill had with paper waste from corrugation and wrinkling? They had all virtually disappeared.
Then we analyzed the rolls for a five-month period after installation to validate production improvements. Honestly, our findings didn’t surprise us. But they certainly did raise the eyebrows of our customer. We found a first-month reduction of 10% in caliper variation. Plus, a reduction in variation of 5% over five months compared to the previous rolls that only ran four months! Proof that with just even one PRG ground roll, the machine was generating higher profitability.
The manufacturer was so impressed by the paper quality and savings resulting from our serviced roll, that it asked us to grind two additional rolls to be used in the future. We’re both now looking forward to calculating the savings that two of our rolls will generate.
The manufacturer was running a large fine paper machine with a two-roll calender stack. The rolls had been running for only four months before corrugation issues were noticed. Further inspection showed barring and feedlines in the calender roll face. The rolls might have only been in production for a few months, but they needed servicing again. Right away. Even if it meant incurring an unplanned and expensive downtime, something had to be done and done right away. The paper coming off the machine was unsellable.
In need of an expedited grind, the company reached out to us to service the top roll. We were able to receive the roll, grind it, and return it within seven days. Once installed, the PRG roll made an immediately noticeable difference to the production line and the quality of paper coming off of it. Machine operators reported that the rolls were running better than ever had before. And most importantly, the past issues that the mill had with paper waste from corrugation and wrinkling? They had all virtually disappeared.
Then we analyzed the rolls for a five-month period after installation to validate production improvements. Honestly, our findings didn’t surprise us. But they certainly did raise the eyebrows of our customer. We found a first-month reduction of 10% in caliper variation. Plus, a reduction in variation of 5% over five months compared to the previous rolls that only ran four months! Proof that with just even one PRG ground roll, the machine was generating higher profitability.
The manufacturer was so impressed by the paper quality and savings resulting from our serviced roll, that it asked us to grind two additional rolls to be used in the future. We’re both now looking forward to calculating the savings that two of our rolls will generate.