Heat Transfer Roll Repairs

We Can Restore Your Chill Roll to Like-New Condition

This is an example of how Menges Roller Company engineers work with customers in the flexible packaging market to refurbish chill rollers and fabricate replacement shells and tubes.

Heat Transfer Roll Repairs, The Start of Rebuild Process

Before: The outer shell is removed, the first phase in Menges' comprehensive heat transfer roll refurbishing process.

With the idea of completely refurbishing this heat transfer roller, Menges Roller company is in the process of performing a service that rebuilds inner tubes and applies new chrome to the outer tube, a service that generates substantial customer satisfaction and works to improve thermal transfer.

After Complete Rebuild

After: Here we see the roller after being completely rebuilt. It looks like new, and is ready to perform like new. This is what our heat transfer roll repairs can do.

This image indicates what can happen when heat transfer rollers do not complete acid flushing and washing services from Menges Roller Company.

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.

Because Menges Roller Company is one of the best vendors specializing in chill roller rebuilding, web heating and cooling can be restored eastily, especially for customers in the flexible packaging, coil converting and paper laminating industries.

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 !

As part of a comprehensive chill roll repair and service offering, Menges Roller provides new chrome finishes and removal of worn plate, available through their location in Wauconda, IL, and provided to customers worldwide.

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.

Menges Roller, in this image, is providing a service that rebuilds the inner shell of chill heat transfer rolls, which is necessary to processors of blown film, wet paper, laminated wood, and adhesive curing applications.

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.

During the process of rebuilding and refurbishing clogged heat transfer rolls, Menges will remove the outer shell and provide new components for the inner shell, as seen here.

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.

Tube repairs for chill rolls are often completed by Menges Roller Company, and this image shows a perfect example of these important flowrate restoration processes, which are available for packaging, plastic, paper and flexible electronic manufacturers.

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.

After Menges Roller rebuilds the liquid-filled chamber on a chill roll, it fabricates new roller components such as the outer tube, then installs the shells together, as this shows.

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.

Cylindrical grinding to prepare for new chrome plate on a chill rollers is all part of the rebuilding and refurbishing process that Menges Roller offers to converters and extruders.

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.

This image shows the results of a complete chill roll rebuild, completed by Menges Roller Company, as part of their shell refurbishing and resurfacing options.

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 our Request A Quote button today and get started on our industry-leading heat transfer roll repairs from Menges Roller Company – the leaders in double-shell technology. We’ll help you run faster, reduce waste and produce a better product.

Request A Quote

PRODUCTS & SERVICES FOR HEAT TRANSFER ROLLERS

As a full-service roller company, Menges offers a full range of support services & products.

Roller Design & Engineering

This page shows the positive results of contracting Menges Roller to provide roll design and engineering services, which include CFD modeling and other innovative uses of computational fluid dynamics.

  • Award Winning Design Services
  • For Perfect Temperatures

Heat Transfer Roll Rebuilding

With a significant number of chill rollers refurbished every year at Menges Roller company, as indicated here, customers see improved performance, reduced clogging, and better thermal transfer.

  • Menges Can Rebuild Your Roll
  • Less Expensive Than New Roll

Chrome & Specialty Finishes

At Menges Roller, chill rollers receive new chrome plate and nickle finishes, including flame sprayed and plasma options, as indicated on this webpage.

  • For New & Refurbished Rollers
  • Mirror Chrome, Nickel & More

Acid Flushing of Liquid-Filled Rollers

When Mengse Roller rebuilds a thermal roller, it often recommends acid washing or flushing to eliminate scale and improve heat transfer fluid flow, and many customers are very satisfied with this technical analysis, as this page details.

  • Important Maintenance Procedure
  • Flushes Away Clogs & Coagulants

Cylindrical Grinding & Polishing

This is link to cylindrical grinding services from menges roller also chrome grinding and chrome refinishing for industrial rollers and cylindrical polishing

  • Part of Chrome Re-Plating Jobs
  • Or to True-Up Out of Round Rolls

Thermal Transfer Fluids

Chill rollers manufactured by Menges Roller Company are designed using CFD Technology, and often times Paratherm thermal transfer fluid is part of this equasion.

  • We Work Exclusively with Paratherm
  • Fluids to Match Any Application

Protective Roller Covers

When rebuilding a chill roller, which includes new chrome plating or nickle plate, customers may purchase protective roller covers for their high-perofrmance industrial roller.

  • Protect Your Chrome Finish
  • Custom Fit Padded Rollcovers

Chillers & Temperature Control Units

In order to optimize the performance of chill rolls made by Menges, we utilize heating units from Delta T, which provide outstanding thermal control.

  • Custom Chiller & Heating Units
  • Work Perfectly with Menges Rolls

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 to discuss the heat transfer roll repairs that we can do for you. Menges will rebuild that malfunctioning chill roller for a fraction of the cost of a new roller.

Call 847-487-8877 or click the Request A Button to contact a Menges Engineer and discuss your repairs.

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.

Request A Quote

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 with our heat transfer roll repairs.

Rebuilt heat transfer rollers are guaranteed not 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.