Heat Transfer Chill Roll Repairs & Rebuilds
We Can Restore Your Chill Roll to Like-New Condition
Start of Rebuild Process
Before: The outer shell is removed, the first phase in Menges' comprehensive heat transfer roll refurbishing process.
After Complete Rebuild
After: Here we see the roller after being completely rebuilt. It looks like new, and is ready to perform like new.
Inner Shell for Refurbishing
Before: Interior of poorly-functioning chill roll. This double-shelled roller was never acid flushed, and performance steadily declined. The roller will have to be refurbished.
Refurbished Inner Shell
After: Menges Technicians have refurbished the inner shell. The tube is cleaned-up, new wraps installed, and siphons re-bored. A new outer shell is next.
REBUILDING DOUBLE-SHELL ROLLERS - COMPLEX BUT COST EFFECTIVE (AND ONLY MENGES CAN DO IT):
- The outer shell is removed. Ususally a new one is fabricated, but sometimes the old one can be saved.
- Inner shell is turned (removing rust & debris), then treated with rust inhibitor (an upgrade option).
- New spiral wraps are installed on inner shell (mimicing old wrap angle or modified for higher/lower velocity).
- New outer shell is fabricated to precise specifications, meeting the desired inner cavity volume dimensions.
- Bores & siphon tubes are refurbished or replaced (depending on roll design, monoflow or duoflow).
- Roller is completely re-assembled: new outer shell is married to inner shell, leak-checked and balanced.
- New chrome plate (or other surface finish) is applied to outer shell, then polished to the desired Ra value.
REBUILDING A CHILL ROLLER - FROM ZERO TO HERO IN 7 EASY STEPS !
Chill Roll Requiring Rebuild
1 - This chill roller came to Menges Roller in desperate need of refurbishing. The roller has a very poor flowrate, with unacceptable thermal transfer, plus badly damaged chrome.
Old Inner Shell
2 - The first thing the Menges Team did (after a thorough evaluation) was remove the outer shell, which was so damaged it was discarded, but this inner shall can be saved.
Refurbished Inner Shell
3 - The inner shell has been turned on a CNC lathe to renew the surface, and new spiral baffle wraps have been installed. This will next be machined to achieve a specific OD.
New Rough Outer Shell
4 - This is a rough-cut of the new outer shell. The ID is right where we want it, and the OD will be machined after installation on the inner shell. Note the counter-bore and weld chamfer.
Outer Shell Tacked On
5 - The new outer shell has been fitted to the refurbished inner shell. For now, the outer shell is just tack-welded. At final assembly, the circumference will be welded and leak tested.
Grinding After Total Assembly
6 - The assembled roller is now at Menges' precision OD grinding station. After a very exact OD is achieved, it will be chrome plated. That chrome plate will then be precision ground & polished.
Completely Rebuilt Chill Roll
7 - Our chill roll has been completely rebuilt and is now ready to perform! The roll will be used in a plastic bag line. Notice the mirror finish, with a 1-3 Ra value. This rebuild was completed for a fraction of the cost of a new chill roll.
LETS GET STARTED!
The Menges Team will analyze your needs to determine the optimal roll configuration for your application. Call 847-487-8877 or click today and get started on an industry-leading heat-transfer roller from Menges Roller Company – the leaders in double-shell technology. We’ll help you run faster, reduce waste and produce a better product.
PRODUCTS & SERVICES FOR HEAT TRANSFER ROLLERS
As a full-service roller company, Menges offers a full range of support services & products.
THE SOONER YOU FIX IT, THE SOONER YOU'LL BE UP AND RUNNING !
Chill rollers are the key to many processes - and their performance is critical. Low flowrates & poor thermal transfer put your production line at risk - and nobody wants that. As a plant manager, you're paid to fix these problems - which is why you need to call Menges Roller. Menges will rebuild that malfunctioning chill roller for a fraction of the cost of a new roller.
Call 847-487-8877 or click the button today to contact a Menges Engineer.
It's your first step toward getting your temperature modification process back on track. We're here to help you run faster, reduce waste and produce a better product.
Double-shelled rollers that are exhibiting low flowrates and poor thermal transfer can be rebuilt & refurbished. This is a substantial cost saving versus a new chill roll, and we guarantee the performance of rebuilt rollers.
Rebuilt heat transfer rollers are guaranteed no to leak, and you'll see the thermal performance of a 'young roller.'
Speak to a Menges Engineer for more on this cost-saving, efficiency-enhancing service.
Because Menges is so well equipped - with a complete machine shop & fabrication plant - "open roller surgery" on your heat transfer roller is no problem. The most common approach is to remove the old outer shell, re-furbish the inner shell (complete with a new spiral wrap), re-drill & tap any components, fabricated & install a new outer shell, then finish with a new chrome plated surface.
We also offer an array of basic repair & modification services for double-shelled rollers.