Bluegrass Roller goes through a very extensive process when diagnosing your roller for repair, refurbishment, or replacement. We will then advise you of any necessary work or repairs that are needed. We are committed to providing you with customer-driven quality service every time.
When your roll arrives in our facility it is logged in and goes through a thorough inspection - both visually and dimensionally. Detailed information such as roll description, roll dimensions, and bearing information is recorded. Any wear or failure is documented at this time.
A value-added service that ensures your roll is ready when we deliver it back to you. We will work with you to establish a preventative roll maintenance program that helps to ensure your equipment stays running. Roll Maintenance includes, but is not limited to: Shaft removal and installation; seals, bearing and bearing housing removal; installation and rebuilds.
During this step we prepare your roll for the build process. If it is an existing roll, the old compound is removed and the roll body is cleaned of any remaining compound, dust, or debris. The appropriate primer and adhesive are then applied. If it is a new core, the roll body is lightly sanded and then cleaned of any dust or debris. The appropriate primer and adhesive are then applied. Once the primer and adhesive have been applied, it is allowed to dry. Great care is taken not to contaminate the area of the roll that has been prepped for the compound. For this reason, each roll is wrapped until ready for the build process.
This is the stage in which the correct compound is applied to the roll, via a state of the art Roll Builder. By monitoring the temperature, speed, and pressure during this process, we are ensured a consistently built roll. The Roll Builder travels along its tracks laying even width strips of uncured compound to the roll body. Once enough compound has been applied, the roll is then readied for the grind process where it will be ground to the finished diameter.
This step is where the magic happens. The roller is placed inside an electric autoclave at a specific temperature, for a specific time, and under a specific amount of pressure. As the roller heats up, the uncured compound begins to flow and the cross-linking between the uncured compound, adhesive, and primer takes place to create the bond to the core.
Grind is one of the last stages of the process. Roll Grind is the process in which the customer’s desired specifications are met. The grind operator reviews all the dimensional criteria and visually inspects the roll before starting the grinding process. Critical measurements are taken twice to ensure the proper set up. From the setup of the grinder to the final cut on the roll, the operator monitors the roll for visual and dimensional accuracy. Any specialty grooving, crowning, or undercuts take place during this stage of the process.
Quality is manufactured into your roll throughout the entire process. For this reason, final inspection starts the moment the roll is pulled for grinding. Measurements are taken and documented throughout the grinding process to ensure the customers desired specifications are met. If at any point there is a question or concern about a roll, the process is stopped until the issue has been resolved. Once finished, the roll is wiped down, wrapped, and staged for shipping.