A converting facility was challenged with a product exhibiting poor adhesion, wet/dry spots, scrap, and customer complaints. These issues began immediately after the installation of a new rubber-covered applicator roll.

Although the roll was technically meeting the specified tolerance, the 0.003" taper was using almost all of the allowable gap tolerance for a glue application. The taper in the roll was creating high and low spots across the sheet, leading to inconsistent lamination, unsellable product and escalating scrap.

Precision Roll Grinders partnered with the converting facility to determine new roll tolerances that considered the roll taper relative to the machine's operating gap. These tighter tolerances would allow consistent glue application across the width of the machine.

After installing Precision Ground rolls, with new tighter tolerance requirements, wet/dry spots and inconsistent lamination were eliminated. The converting facility restored product quality and restored customer confidence.

Even when rolls fall within “acceptable” tolerances, the relationship between roll geometry and machine operating gaps must be considered. In this case, tightening tolerances and eliminating taper relative to a narrow glue gap ensured consistent lamination, provided significant savings, and eliminated scrap.

Contact Precision Roll Grinders to learn more!