Copper Chill Rolls

Copper Rolls Can Chill Or Heat More Efficiently Than Steel Rolls

copper chill rolls are covered with chrome to improve strength and corrosion

Copper Chill Rolls

Chill rollers made out of copper can greatly increase line speeds and allow converting companies to produce their product up to 10X more efficiently.

High quality finishes and reduced cooling costs are why leading converting companies around the world are converting steel chill rolls to copper chill rolls. 

Our construction techniques provide the strength your plant is looking for. Converters and OEMs woldwide trust Menges to help them increase line-speeds and improve efficiency. 

copper chill rolls in process with bored tube

Versatile For Many Industries

Menges Roller can produce copper chill rolls for laminators, film producers and leaders in the paper manufacturing industries. Customers are always trying to push the limits of line speeds.

By using a Menges Roller copper chill rolls, customers are increasing line speeds while becoming more efficient. Copper chill rolls require about 40% less cold water (or glycol) vs steel. This allows converters to reduce fluid flows or reduce chiller output. 

copper chill rolls ready to be processed by menges roller company

Copper Tubes Equal Strength

The seamless copper tubes can also be chrome plated and provide the strength customers are looking for.

Companies who are looking to increase their line speeds trust Menges to do so. 

Utilizing our Computational Fluid Dynamics (CFD) engineering capabilities we can prove the great efficiency copper shells provide. 

Why Copper Chill Rolls:

  • Cool Product More Efficiently

  • Increase Line Speeds

  • Produce High Quality Finishes

  • Greatly Reduce Energy Consumption

  • Reduce Internal Corrosion

  • Can Improve Heating Or Cooling

copper chill rolls in process with engraved pattern

Copper vs Steel

Copper’s thermal coefficient of heat transfer can be up to 10x that of steel. This means you can transfer cooling at almost 10x the rate by using a copper chill roller instead of a steel chill roller.

By using a copper cylinder this also reduces the need for higher flow rates which lead to higher costs in chilling units. By purchasing a copper roller, this leads to a domino effect of savings throughout your film or paper line!

For example: If a plant runs 40°F fluid though 2 rollers (1 steel, 1 copper) at 100 GPM each, and each roller is subjected to the same heat load, the copper roll would run, in this case, 40% cooler on the body. This would allow the converter's substrate to cool more quickly without increasing the rolls size. Line-speeds can be increased, cooling can be decreased, and profit margins optimized. 

copper chill rolls outer shell alongside steel and aluminum tubes

Plot and Roller Comparisons

These simulations show how a copper shelled chill roll is much more effective at transferring heat out of a substrate. Both simulations were run at the same specifications, only one had a copper and one had a steel shell.

engineering design for copper chill rolls

Copper Chill Roll Temperature Profile Diagram

This illustration shows the difference in temperature across the copper shelled roller. 

This copper shelled roller ran about 40% cooler than the steel roller comparison, see below.

Copper decreases the amount of time needed to cool the web. With decreased dwell times, line-speeds can be increased!

engineering design for steel rollers

Steel Chill Roll Temperature  Profile Diagram

This illustration shows the difference in temperature across a steel roller. 

This difference in temperature distribution shows that the steel roller does not run as cool as the copper chill roll. 

The steel roll gives off a temperature in the 65-70°F range. This is 20+ degrees more than the copper roll with the same flow rate and water input temperature. 

copper chill rolls temperature profile

Copper Chill Roll Profile Illustration

This copper chill roll ran about 25F° cooler on the body of the roller.

Running at a much cooler rate can lead to faster line speeds and a higher production rate, which could lead to an increase in profit.

Copper chill rolls maintain their efficiency longer than steel rollers and require less maintenance because they are better at resisting corrosion and fouling. 

steel roller temperature profile

Steel Chill Roll Profile Illustration

This steel roller did not cool as well as the copper roll with the same flow rate and environment parameters.

Steel rollers are not able to run as fast as copper chill rollers. They also require maintenance to combat corrosion and fouling during their life cycle, which is an extra expense. 

This illustration shows that copper chill rolls provide superior cooling than their steel counterparts.

Ready For A Copper Chill Roller?

If you would like to discuss how copper chill rollers can benefit your line and increase your profit with a Menges Engineer, call us at (847) 487-8877

Click our 'Request A Quote' button to upload your specs, get your project quoted, and ask your questions.

We look forward to making your copper chill rolls!

Working With Menges Roller Company

Menges Roller Company is a leading supplier of high performance heat transfer and chill roller design and manufacturing for the plastic and converting industries. We offer many design options from economical singles shell for basic temperature control to corrosion resistance hybrid designs featuring rubberized inner shells.

Our most popular design is the double shell spiral baffle heat transfer and chill roller. Menges has an award-winning engineering department. In 2014, we won the AIMCAL Technology of the Year Award for our use of computational fluid dynamics. Don’t take chances with companies that don’t understand these complex technologies. Work with Menges and work with one of the most respected names in heat transfer.