Roll change intervals at many mills are set by convention, not by roll condition. Conservative schedules protect paper quality, but that comes at a cost in the form of unnecessary grinding, freight, and outage expenses. Rolls ground to tight tolerances wear evenly and predictably, which allows a mill to trust its own inspection data to extend run intervals with confidence instead of guesswork.

A linerboard mill was running a two-roll calender stack with grinds from Precision Roll Grinders (PRG) on both rolls. The mill had been changing rolls every 12 months, an interval driven more by habit than by anything the rolls were telling them. On the strength of roll condition and paper quality off the calender, the mill extended its target interval to 24 months.

The mill is currently running a full 26-month interval with paper quality holding throughout, beating the 24-month target. Doubling the interval cuts the number of grinds, freight moves, and roll changes in half. That extended interval saves the mill almost $30,000 per year in maintenance costs.

Contact your local account manager for more information.