Another set of ceramic rolls repaired with our innovative solution

Following on from the success achieved with customers in the USA, our unique solution for rebuilding ceramic embedded rolls is going global.

This innovative solution offered by Welding Alloys is attracting growing interest in the cement industry. A plant in India recently reached out to Welding Alloys South Asia to discuss how this solution could benefit their operation, as they had two ceramic rolls that were badly worn.

Typically, when these rolls wear down, they are discarded and replaced. However, replacement of the rolls can be costly and the lead times for the new rolls can be long, so the plant was interested to find out more about our alternative solution. Welding Alloys has invested time in developing a process to successfully rebuild these critical components that involves welding new wear-resistant material onto the worn areas of the roll, using specialised cored wires and techniques.

The Integra^™ services team at Welding Alloys South Asia carried out the job using our advanced welding consumables and proven welding methods. The rolls were rebuilt to their original profile and put back into service at the plant, with the repaired rolls expected to achieve the equivalent or improved service life than that of the original rolls.

Thanks to a culture of continuous innovation, Welding Alloys enables cement plants to extend the service life of ceramic rolls, reducing plant downtime, overall costs, environmental impact and waste. Continuous advancements in welding technologies and materials are expected to enhance the performance of our solution going forward.