How Embossing Roll Maintenance Maximizes Performance and ROI

Engraved embossing roll sets are critical components of a manufacturer’s greatest investment (their production equipment).

Keeping the sets in peak condition ensures longevity of pattern performance. It can also curtail often long periods of downtime waiting for a repair or replacement since many manufacturers find keeping spare rollers on hand to be cost prohibitive.

Finding a happy medium takes a maintenance team with preventive practices in place, and a partnership with engraved roll experts that can come alongside your team with solutions to fit the need.

4 Keys to Embossing Roll Set Maintenance

As with most things, catching embossing roll damage early may not completely prevent a problem, but it does limit its severity. Diligence in monitoring the rollers is required, but what should your team be looking for?

Routine embossing roll set maintenance should include these four things:

1. Pattern wear check. If the engraved roll isn’t producing crisp, uniform pattern impressions, that could be a sign of the need for cleaning, re-chroming, or reconditioning. Re-engraving or replacement are the worst case scenarios, and ideally won’t be necessary prior to the anticipated end of the life cycle.
2. Rubber roll inspection. Rubber rolls should exhibit even surface wear, uniform hardness and circumference, as well as accurate loading pressures. Journal bearings should be well-lubricated, and drive ends should be examined for cracks or other component damage.
3. Steel roll inspection. Steel rolls should be smooth, free of any damage to the element, and brush rolls should rotate freely. As with rubber rolls, journal bearings should be well-lubricated, and drives should be assessed for cracks or other component damage.
4. Roll setup validation. Precision performance depends on making sure roller surface contact and pressures are optimized accurately. Doing so ensures pattern and embossing depth uniformity, and extends embossing roll set life.

The benefits of proactive maintenance can usually be seen in the bottom line:

• Cost savings of up to 90% compared to a fully re-engraved roll or investing in a new roll.
• Downtime minimization — repairs may be done in as little as one week, which is a fraction of the typical 6-8 weeks it takes for embossing roll re-engraving.
• Significant improvement of roll life, which may increase by 3-5x depending on the substrate, industry, roller materials, and certain other variables.

Precision Roll Solutions Repair & Refurbishment Services

Working with proven engraved roll experts, such as Precision Roll Solutions, is a smart way to supplement a preventive maintenance plan. Our technicians work with members of your team to create an annual on-site evaluation program driven by your requirements, production schedule, and the rate of year on your embossing roll set.

Regularly scheduled PRS technician visits bring decades of practical experience to assessing the overall health and potential problem areas of your embossing rolls. What’s more, each visit results in a written status report that helps you keep tabs on performance, and aids in decision-making about roll investments.

Those decisions could lead to a tipping point about whether it makes better budgetary sense to repair rolls or invest in new assets. PRS Repair and Refurbishment services can help your team choose the solution that works best for you.

With help from our Repair and Refurbishment experts, you have more than options. You have actionable next steps — from bringing old rolls back to spec with journal rebuild/replacement, roll surface resurfacing, and rebalancing to customizing new rolls.

Learn more about how a PRS partnership can help you effectively maintain your embossing roll sets and maximize roller life cycles. Contact our team about Repair and Refurbishment services today.