The heart of any roll compaction process is the roll surface. It is common for system efficiency to unknowingly diminish overtime for a number of reasons – employee turn over (both operators & maintenance), changes to the equipment itself, and changes made to the upstream equipment. Gradual production loss can be easily over looked, however one main contributing factor is often wear on the roll surface.
The quality of compact from the rolls is a direct result of the friction between the material and roll surface, which translates to optimal production rate. The condition of the roll surface is critical in order to efficiently draw the material into the rolls. Key system indicators that it may be time to consider roll refurbishment include the following:
Increased Roll Amperage
System Yield is >10% Lower than its Design Capacity
Increased Fines (due to reduced quality of compact)
Increase in Process Temperature
VFS Occasionally Overloads
Roll Refurbishment Options
There are several different ways to refurbish compactor rolls depending on budget requirements, the length of time your process can afford to be down, and ultimately the level of wear on the rolls.
Recut Roll Surface – Depending on the condition of the rolls, severity of wear, and if the material can process with a larger static roll gap, this is the most cost effective option. To be determined after T&I.
Replace Roll Shell – When the roll surface is determined to be worn beyond repair, roll shell replacement is required. This is the next ‘level’ cost effective solution.
Drop In Roll Assembly – This typically applies to larger manufacturing facilities who continuously operate and cannot afford to stop production for long periods of time. A complete drop in roll assembly is required, while the rolls taken out of service can be repaired for the compactor’s next servicing.
Minimize Production Loss
With advanced planning, IPA can have parts available to ensure quicker lead times and reduce production down time.