Sugar Mill Rolls
Components used in sugar mills for the extraction of sugar juices from sugar cane are subject to significant wear problems, where the grinding rolls can be severely impacted. Wear on the grinding rolls leads to decreased grinding production rates and an increase in energy consumption, resulting in higher total costs. To mitigate the effects of wear on equipment used in sugar mills, we offer an array of advanced welding wires and electrodes, as well as automatic and semi-automatic welding machines dedicated to sugar mill applications. We also have technical experts with hands-on technical knowledge and expertise, located across the globe, to support mills in finding the right solution for their specific needs, which is exactly what we did for a prominent sugar mill in the Americas.
After an initial online meeting with the customer, it was agreed that we would undertake a wear audit to assess the rolls and the working environment, where it was identified that the rolls had significant wear after just one season of 185 days of grinding. The wear was causing the rolls’ grinding teeth to lose grip, which was causing lower levels of grinding productivity and deformed teeth. This was leading to reduced juice extraction rates, which in fully optimised mills should be in the high 90s percentile.
Following an on-site inspection with some additional analysis and data gathering, our technical team determined the best solution for addressing the specific wear experienced on the rolls and taking into account the customer’s specific requirements. The proposal involved a solution to protect the roll teeth by hardfacing them with our specially developed cored wires for sugar mill rolls.