ARC International

January 23, 2025

Maximizing Roller Performance: Why Precision Matters in Corrugator and Converting Equipment

Box plants depend on the performance of critical rollers in key equipment such as corrugator single facers, glue machines, corrugator knives, as well as feed sections and print stations on flexo folder-gluers and flexo die cutters. When it’s time to replace these essential components, it’s not just about installing a new glue applicator surface or re-coating meter, doctor, and knife rollers. Nor is it just about adding a fresh laser-engraved ceramic surface on anilox rollers or a new elastomeric surface on feed and wiper rollers. There are numerous critical specifications that must be addressed during roller reconditioning, or the rollers won’t meet the required OEM standards.

Key specifications include dynamic balance, taper, total indicated runout (TIR), bearing surface integrity, gear step accuracy, pilot bore and keyway alignment, as well as bolt hole tolerances. Overlooking any of these details can significantly impact roller performance, leading to costly downtimes and operational inefficiencies.

At ARC International, our engineers begin the reconditioning process by cross-referencing the original OEM blueprint with the customer’s order to ensure a comprehensive inspection of the incoming roller. If we find any deviations in critical tolerances—especially in journals or bolt-on headers—these issues are documented, photographed, and included in a confirmation sent to the customer for approval. If a roller’s journals are too worn or damaged for repair, we may recommend a complete journal or header replacement, or even the fabrication of an entirely new roller base. ARC International is proud to supply newly fabricated rollers to both the corrugated aftermarket and directly to OEMs, adhering to their strict tolerance requirements.

For rollers approved for reconditioning, ARC’s machinists utilize true welding processes, as opposed to the more common spray weld methods used by many competitors. This ensures critical areas like bearing bores and gear step diameters maintain their structural integrity during operation—avoiding concentricity issues that can lead to rejected boxes and operational headaches. Many roller manufacturers lack in-house capabilities for advanced journal and header repairs, outsourcing these tasks to local machine shops, resulting in longer lead times and potential delays. At ARC International, we handle these critical repairs in-house, leveraging advanced equipment and skilled technicians at both our Charlotte, NC, and Las Vegas, NV, facilities to deliver the highest quality results with faster turnaround times.

To experience ARC’s streamlined process and commitment to quality, contact your ARC customer service representative today at 800-526-4569 and ask about our Shipping Made Easy™ program.