FEED ROLL RECORRUGATION

Consists of the following               -  feed rolls being removed from the roller mill         

-          Rolls delivered to our facility where the complete assembly from the rolls, to shafts, keyways, bearings & pulleys will be inspected     

-          Customer  choice to remove pulleys from rolls, we have a 100 ton puller onsite to remove seized pulleys.  Centers on the shaft cannot be damaged, please do not use conventional gear puller.  If the center are damaged centers will need to be repaired prior any roll machining

-          BEARINGS DO NOT NEED TO BE REMOVED FROM THE ROLLS

-          Roll bodies will be machined just below the depth of the previous corrugation to minimize roll diameter loss.

-          Roll bodies will be corrugated to customer specification.   6 – 24 GPI to a sharp point or a land.

-          Pulleys will be installed, rolls inspected, shipped / stored

CORRUGATION  -   the groves on the roll body “pull” the product between the rolls, where the product is cracked.  The force of the rolls does the cracking of the grain.  The larger diameter rolls rely less on the corrugation due to the progressive deep trough created by large diameter rolls ( 24” and higher ).  Smaller diameter  rolls, especially 9” rely heavily on the corrugation due to the shallow through.   For a dry product a sharp corrugation is recommended.  For a high moisture or steam injected product a land is recommended, this will minimize the high moisture product from getting stuck to the roll and being built up.  A corrugation of 6 – 24 GPI ( grooves per inch ) can only be done on Chillcast rolls.  Hollow rolls will be done at ¼” – 3/8” spacing.

CHILLCAST ROLLS  / CENTRIFUGAL CAST ROLLS – soft cast surrounded by hard cast ( 49 -53 rockwell ), 4140 shafts pressed / cast into rolls.  The hard layer on the outside of the roll is aproximatelly  11/16” thick.  Once the rolls are 7/8” smaller in diameter than new, it is not recommended to recorrugate further.  When the hard cast layer is thin it can potentially flake off in large sections,  leaving the rolls useless.  The hard cast layer, cannot be repaired or replaced.  These rolls are special order form world leading European suppliers, with an expected delivery of 3 – 4 months.  We keep limited stock.

HOLLOW ROLLS – these rolls are designed for roller mills with frames / bearings that cannot support the weight of solid cast rolls.  Usually built of heavy wall pipe ( 0.718” – 1.031” wall thickness ).  These rolls will not last as long as chill cast rolls and will not hold a sharp edge as long as the “chill cast rolls”.  Rolls with a wall thickness of ¼” or less cannot be recorrugated.   These rolls are fabricated  as per customer specifications / requests.   All of our fabricated rolls are machined to intereference  fits, pressed together, then welded.  This greatly minimize cracking of welds.   Delivery 2 -3 weeks.  We do not keep stock.

ONE DAY ROLL SERVICE                 We offer a one day turn around on roll recorrugation.  Most rolls can be done in a regular shift.  Larger rolls such 20”dia. X 42” long with a fine corrugation can take up to 13 hrs / set.   This service must be booked in advance, machines will be allocated for your time slot.