Food industry

Surface engineering, drum dryer coatings and component refurbishment for food processing equipment

Food processing equipment operates in demanding environments where wear, corrosion, moisture, cleaning processes, temperature and continuous production can gradually affect critical components and functional surfaces.

At the same time, food production can place specific requirements on surface condition, cleanability, wear resistance and, where applicable, suitability for food contact.

PR Rolls provides industrial coatings, surface engineering, on-site services and workshop refurbishment for food processing equipment and production components.

Our capabilities include:

• Food-grade coating solutions for suitable applications
• Drum dryer grinding and coating
• Industrial coatings and surface engineering
• Wear and corrosion protection
• On-site machining and grinding
• Dimensional restoration
• Shaft and journal repair
• Roll and cylinder refurbishment
• Pump and valve component restoration
• Hydraulic component refurbishment
• Precision finishing

The objective is to restore valuable production equipment and engineer the functional surface according to the actual application.

Maintenance Challenges in Food Processing

Wear, corrosion and surface condition affect production

Food processing equipment can be exposed to several deterioration mechanisms simultaneously.

Common challenges include:

• Mechanical and abrasive wear
• Corrosion and erosion
• Acidic process conditions
• Scratches and surface damage
• Dimensional wear
• Damaged sealing surfaces
• Product sticking and build-up
• Coating deterioration
• Difficult-to-clean surfaces
• Shaft, journal and bearing area wear

The appropriate solution depends on what the component does, why the existing surface is deteriorating and what properties the restored surface needs to provide.

PR Rolls therefore approaches maintenance from both a mechanical and surface-engineering perspective.

Inspect → Identify → Restore → Engineer the surface → Finish → Verify

Tecno Diamond FS – Food-Grade Coating for Drum Dryers

A durable functional surface developed for food industry applications

PR Rolls has developed Tecno Diamond FS, a food-grade approved thermal coating specifically designed for demanding food industry applications.

The coating is particularly well suited for drum dryers, where the cylinder surface can be exposed to continuous wear, acidic conditions and intensive scraping.

Tecno Diamond FS was developed as part of the FoodSafe project, combining PR Rolls' experience in carbide coating technology with the specific requirements of food processing applications.

The coating has passed EU-recommended migration tests performed by an independent external laboratory, and a Declaration of Conformity has been prepared for Tecno Diamond FS.

This makes it possible to combine demanding functional surface properties with documented food-grade suitability for the intended applications.

Drum Dryer Grinding & Coating

Restore the existing cylinder instead of replacing it

In drum drying applications, the cylinder surface is a critical part of the production process.

Continuous operation, scraping, wear and process conditions can gradually deteriorate the functional surface.

Tecno Diamond FS has been developed to provide properties particularly relevant to these demanding applications, including:

• High wear resistance
• Resistance to intensive scraping
• Protection against acidic conditions
• A homogeneous and consistent surface

When an existing drum dryer surface becomes worn or damaged, replacing the complete cylinder is not necessarily the first solution.

PR Rolls can restore suitable existing cylinders through a complete surface engineering process:

Inspection → Measurement → Grinding → Surface preparation → Tecno Diamond FS coating → Final finishing and quality control

Where technically appropriate, grinding and coating can be performed on-site at the customer's production facility, reducing the need to dismantle and transport large cylinders.

The objective is to create a renewed functional surface while preserving the existing cylinder structure.

Metallic Coatings for Food Industry Applications

Different surfaces for different production requirements

Tecno Diamond FS is one specialised solution within PR Rolls' broader surface engineering capabilities.

Food processing equipment contains many components where wear, corrosion, erosion or dimensional deterioration can limit service life.

Depending on the application, PR Rolls can provide metallic coatings and surface solutions for requirements including:

• Wear resistance
• Corrosion resistance
• Erosion resistance
• Dimensional restoration
• Controlled surface properties
• Application-specific surface finish

Potential components include:

• Rolls and cylinders
• Drum dryers
• Shafts and journals
• Pump components
• Valve components
• Hydraulic components
• Moulds and tools
• Sleeves
• Bearing areas
• Other production equipment

The coating system is selected according to the component, substrate, wear mechanism, operating environment and required final surface.

Wear & Corrosion Protection

Engineer surfaces for demanding process conditions

Repeated mechanical contact can gradually change both the dimensions and surface properties of food processing components.

At the same time, moisture, acidic conditions, process media and cleaning environments can contribute to corrosion.

Where the underlying component remains technically suitable, PR Rolls can restore the existing surface and provide a new functional coating.

A typical process can include:

Machining → Surface preparation → Coating → Grinding → Precision finishing

Depending on the application, carbide-based and other metallic coating technologies can provide durable functional surfaces for demanding production environments.

The appropriate coating should always be selected according to the actual wear and corrosion mechanisms.

Pumps, Valves & Process Components

Restore worn functional surfaces

PR Rolls' food industry services extend beyond rolls and cylinders.

Pumps, valves and other process components contain critical surfaces where relatively localised wear or corrosion can affect the performance of the complete component.

Suitable applications can include:

• Pump shafts
• Sleeves
• Seal areas
• Bearing areas
• Valve components
• Shafts and journals
• Other precision process surfaces

Depending on the component, restoration can combine machining, metallic coating or plating and precision finishing.

This can allow a worn functional area to be restored while preserving the existing component.

Shaft, Journal & Bearing Area Repair

Restore dimensions instead of replacing the complete component

Shafts, journals, bearing seats and sealing areas can deteriorate through wear, corrosion, fretting or mechanical damage.

PR Rolls can restore suitable areas using:

• Machining
• Grinding
• Metallic coating
• Brush plating
• Dimensional restoration
• Precision finishing

The affected area can be rebuilt and finished to the required dimensions and surface condition.

This can provide an alternative to replacing an otherwise serviceable component because of localised damage.

Hydraulic Components, Moulds & Tools

Surface restoration for valuable production components

PR Rolls' surface engineering capabilities can also be applied to other food processing and production equipment.

Suitable applications can include:

• Hydraulic cylinders and components
• Piston rods
• Moulds
• Tools
• Machine components
• Bearing and guide areas
• Other wear-exposed metallic surfaces

Typical problems include wear, corrosion, scratches, dimensional errors and local surface damage.

Where only a limited area is affected, localised restoration can help preserve the original component rather than replacing it.

On-Site Machining, Grinding & Coating

Bring the repair technology to the equipment

Large food processing components can be difficult or inefficient to transport to a workshop.

PR Rolls provides on-site machining, grinding and coating for suitable industrial equipment.

Depending on the application, services can include:

• Turning
• Milling
• Grinding
• Line boring
• Drilling
• Surface preparation
• Thermal spray coating
• Precision finishing

On-site service can reduce dismantling, transportation and reinstallation requirements.

This is particularly relevant for large drum dryers and other cylinders where the component can be restored directly in the production facility.

Workshop Maintenance & Refurbishment

Complete restoration for removable components

When a component can be efficiently removed, PR Rolls can provide complete workshop refurbishment.

Depending on the component, the process can include:

Inspection → Measurement → Mechanical repair → Machining → Grinding → Surface restoration → Coating → Precision finishing → Balancing

This provides two complementary maintenance routes:

Large or fixed equipment → On-site service

Removable component → Workshop refurbishment

The appropriate method depends on component size, condition, surface requirements and maintenance situation.

Food Contact & Surface Requirements

Food-contact suitability must be evaluated for the specific coating system
Not every industrial coating is suitable for direct food contact.

A coating should not automatically be considered food-grade simply because it is metallic or provides good wear and corrosion resistance.

Where a coated component comes into contact with food, relevant factors can include:

• Specific coating material and coating system
• Substrate
• Finished surface condition
• Intended food contact
• Process conditions
• Operating temperature
• Cleaning and sanitation methods
• Mechanical wear
• Applicable food-contact requirements

Tecno Diamond FS is different from PR Rolls' general industrial coating portfolio because it has been specifically developed for food industry applications and has passed EU-recommended migration tests performed by an independent external laboratory. A Declaration of Conformity has also been prepared for the coating.

Other PR Rolls industrial coatings should not automatically be considered suitable for direct food contact unless suitability has been established for the specific coating and application.

Surface Finish & Cleanability

The final surface is part of the coating solution

Selecting the coating material is only one part of surface engineering.

The final surface condition can be equally important.

Depending on the application, grinding and precision finishing can be used to achieve the required:

• Dimensions
• Geometry
• Surface roughness
• Surface uniformity
• Functional characteristics

For food processing equipment, the final surface should also be considered in relation to the intended process, cleaning requirements and applicable hygienic requirements.

PR Rolls therefore approaches coating as a complete surface system:

Substrate → Surface preparation → Coating → Grinding → Finishing → Verification

Typical Food Industry Applications

PR Rolls' maintenance and surface engineering technologies can be applied to suitable equipment throughout food production and processing.

Typical applications can include:

• Drum dryers and drying cylinders
• Rolls and cylinders
• Pumps and pump components
• Valves
• Shafts and journals
• Bearing and sealing areas
• Hydraulic components
• Moulds and tools
• Processing equipment
• Packaging and converting equipment
• Other production-critical components

The deciding factor is what the component needs to do, which environment it operates in and what properties are required from the functional surface.

Repair, Recoat or Replace?

Extend the service life of valuable production equipment

Wear or corrosion does not automatically mean that the complete component needs to be replaced.

Depending on its condition, PR Rolls can evaluate whether the appropriate strategy is to:

Repair – correct local damage.

Restore – rebuild worn dimensions.

Recoat – renew the functional surface.

Refurbish – restore mechanical and surface condition.

Upgrade – select a surface better suited to the operating conditions.

Replace – when restoration is no longer technically appropriate.

This condition-based approach helps utilise the remaining service potential of valuable production components.

Why PR Rolls for the Food Industry?

Combine surface engineering with industrial maintenance expertise

A functional coating can only perform as intended when the underlying component provides the correct foundation.

PR Rolls combines:

Inspection + Machining + Grinding + Surface preparation + Industrial coating + Precision finishing + Workshop refurbishment

Our capabilities extend from Tecno Diamond FS and drum dryer restoration to pumps, valves, shafts, hydraulic components, rolls, moulds and other food processing equipment.

For large components, PR Rolls can also bring specialised grinding and coating technology directly to the production site.

The objective is not simply to apply another coating.

The objective is to restore the component and create the functional surface required for reliable production.

Frequently Asked Questions About Food Industry Services

What is Tecno Diamond FS?
Tecno Diamond FS is PR Rolls' food-grade approved thermal coating developed for demanding food industry applications, particularly drum dryers. It has passed EU-recommended migration tests performed by an independent external laboratory, and a Declaration of Conformity has been prepared for the coating.

Is Tecno Diamond FS suitable for drum dryers?
Yes. Tecno Diamond FS has been specifically developed for demanding drum dryer applications where the surface can be exposed to wear, acidic conditions and intensive scraping.

Can PR Rolls grind and coat drum dryers on-site?
Yes, where the component and site conditions are suitable. PR Rolls has developed on-site capabilities for grinding and coating existing food industry cylinders, reducing the need to remove and transport large components.

Are all PR Rolls coatings suitable for food contact?
No. Food-contact suitability must be established for the specific coating system and application. Tecno Diamond FS has specifically undergone EU-recommended migration testing and has a Declaration of Conformity.

What other food industry components can PR Rolls repair?
Suitable applications can include rolls, cylinders, shafts, journals, pumps, valves, hydraulic components, bearing areas, moulds, tools and other industrial production components.

Can worn shafts and bearing areas be restored?
Yes. Suitable worn areas can often be restored using machining combined with metallic coating, brush plating or other dimensional restoration technologies.

Does PR Rolls provide workshop refurbishment?
Yes. Suitable removable components can undergo complete refurbishment combining mechanical repair, machining, grinding, coating and precision finishing.

Restore the Component. Engineer the Surface.

Food processing equipment depends on surfaces that can withstand demanding production conditions while meeting the requirements of the specific application.

PR Rolls combines food industry coating technology, on-site grinding and coating, industrial surface engineering, machining and component refurbishment to restore suitable production equipment.

For drum dryers, Tecno Diamond FS provides a food-grade approved functional surface developed specifically for demanding food industry applications.

Our expertise also extends to pumps, valves, shafts, hydraulic components, rolls, cylinders, moulds, tools and other production-critical equipment.

Inspect → Restore → Engineer the surface → Finish → Verify → Return to production

Contact PR Rolls to discuss Tecno Diamond FS, drum dryer restoration or another food industry surface engineering and maintenance requirement.