What you can expect

We offer perfection in the µm range

Precise.Ground.Perfect.

With sophisticated electroplating procedures and CNC-controlled machines and with specialists who are used to achieving the best results for our customers, we get the right surface quality for every application.

From our perspective simply precise is not precise enough.

When we grind a roll, we achieve a deviation of less than 2 µm in terms of cylindricity and concentricity with a face length of up to 10,000 millimeters by CNC control.

A hair is approximately 70 µm thick and therefore not an exact benchmark for us.

Coating

With chrome and nickel

Chrome plating

Hard. Low Friction. Durable.

Chrome plating of rolls with a diameter of up to 2,000 mm, a length of up to 6,000 mm and a weight of 20,000 kg

Hard chrome plating in vertical tanks

Any demanded layer thickness can be provided

Degassing is possible

Because surface hardness is important, we are specialized in hard chrome plating. Our chrome layers have a hardness of approx. 65 HRC. We have a total of seven vertical tanks for different sized rolls.

All tanks are supplied with computer-controlled rectifiers as a power source. The modern rectifiers vary the current in intensity (pulse mode) and direction (reverse mode), which guarantees a denser crystal structure and ensures exact reproducibility.

With our special chrome plating technology, we do not only produce any demanded layer thickness with the best possible microstructure quality but also provide high-quality electrolytic matting. Modern cooling equipment keeps the electrolyte temperature permanently at the optimum level. If required, we can degas the roll:
a process where the hydrogen emerged during chrome plating is degassed out of the roll by controlled tempering.

Nickel plating

Resistant. Firm. High quality.

Nickel plating of rollers with a diameter of up to 1,000 mm, a length of up to 4,200 mm and a weight of up to 7,000 kg

In addition to chrome plating or as an alternative

Repair of the roll surface

Nickel plating offers the possibility of repairing rolls that show distinct signs of wear due to high use during the production and over time they have fallen below their original diameter.

Depending on the requirements of the roll surface, nickel plating can either be used as a supplement to chrome plating or an alternative. This is because our nickel plating comes close to the hardness of hard chrome plating (approx. 55 HRC). A nickel layer can also be easily provided as a substrate in combination with a chrome-plated top layer without any restrictions regarding production quality.

Refining

With a wide range of surface roughness and roll profiles

Grinding

Precise. Ground. Perfect.

Precise grinding of rolls with a diameter of up to 3,500 mm, a length of 10,000 mm and a weight of 40,000 kg

Grinding at operating temperature

CNC technology provides any demanded roll face profile

Our grinding machines can achieve the highest possible precision for different types of rolls. We even process particularly large rolls with a diameter of up to 3,500 millimeters up to a maximum grinding length of 10,000 millimeters. For example, we are able to grind a calender roll weighing 25,000 kg and the dimension of Ø 1,000 x 5,000 mm face length to an axis parallelism of less than 1 µm.

Seven grinding machines with traversing grinding saddle are currently in use, while six further grinding machines with travelling workpieces are used for smaller rolls. All are equipped with a modern CNC control system. This means that any deviation from the target profile can be limited to 1 µm. The grinding result, run-out and concentricity are measured and documented electronically.

Notable: We also process rolls at operating temperature which means that we are grinding rolls at the same temperature as the customer has set in his production plant. With the help of powerful heating systems, we can grind at all temperatures between 20 °C and 220 °C. As with cold grinding, the profile error can be limited to 1 µm.

We also grind and polish hard-coated rolls to the demanded surface roughness and roll profiles. Depending on customer requirements, we process these rolls at ambient temperature or at higher operating temperatures of up to 220 °C.

Finish

Matt. Polished. High gloss.

Polishing for glossy surfaces

Matt finish for matt surfaces

Combination of polishing and matting is possible

The final step of processing denominated as finish consists of two main areas: Polishing and matting. This treatment is largely responsible for the properties and appearance of the surface.

The finish is used to create the roughness of the roll surface. We offer matting in a range of up to Rz 50 μm and more. For polishing, we offer a range from simple industrial polishing to an absolute mirror finish of up to Rz 0.05 μm.

Machining

Maintenance and repair of rolls

Service

Refurbished.Checked. Ready for operation.

Repair and maintenance

Restoration of journal contours

Our mechanical workshop is very well equipped for a wide range of maintenance and repair work on your rolls and other cylindrical workpieces. We ensure that repairs are carried out quickly and smoothly so that you can continue to produce at a high level.

Our services include, for example, replacing the plugs of peripherally drilled calender rolls, regardless of the design principle. Then we check the tightness by pressure test at ambient temperature or at working temperature.

We can rebuild and/or modify the journal contour of your roll.

Here is an overview:

Flushing and cleaning the inside of the rolls
Plug replacement and resealing of calender rolls
Journal repair
Service and maintenance of the roll