Paper and cardboard industry

On-site services, workshop maintenance and surface engineering for paper and board machines

Paper and board machines operate continuously with demanding requirements for runnability, geometry, surface condition, alignment and rotating equipment reliability.

Wear, corrosion, contamination, vibration and dimensional changes can gradually affect critical machine components. At the same time, many of these components are large and deeply integrated into the production line, making removal and transportation both time-consuming and expensive.

PR Rolls provides specialised on-site services, workshop maintenance and surface engineering solutions for paper and board mills.

Our capabilities cover critical components throughout the production line – from vacuum and suction rolls to dryer cylinders, guide rolls, spreader rolls, calender rolls, reel drums and winding applications.

Depending on the component and maintenance requirement, PR Rolls can provide:

• On-site grinding
• On-site machining
• Industrial coatings and surface engineering
• Measurement and alignment
• Field balancing
• Workshop maintenance and refurbishment
• Dynamic balancing
• New and refurbished spreader rolls
• Dryer cylinder maintenance
• Vacuum and suction roll modifications
• Dryer section optimisation
• Component lifecycle solutions

The objective is not simply to repair individual components.

The objective is to restore the geometry, surface functionality and mechanical condition required for reliable paper and board production.

Maintenance Challenges in Paper & Board Production

Surface condition, geometry and mechanical performance are interconnected
A paper or board machine consists of hundreds of interacting components.

A change in one roll or cylinder can affect the process around it.

Typical maintenance challenges include:

• Wear
• Corrosion
• Surface damage
• Contamination and build-up
• Poor release
• Insufficient traction
• Geometry deviations
• Misalignment
• Vibration and imbalance
• Bearing and journal wear
• Blocked or damaged suction holes
• Damaged grooves
• Dryer cylinder surface deterioration
• Changes in machine or production requirements

The appropriate maintenance strategy therefore depends on both the condition of the component and its function in the production process.

PR Rolls combines measurement, machining, grinding, coating, finishing and balancing capabilities to address these problems as complete maintenance solutions.

On-Site Services for Paper & Board Machines

Bring specialised equipment to the machine

Large paper machine rolls and cylinders do not always need to be removed when they become worn or damaged.

PR Rolls specialises in performing demanding machining and surface restoration directly at the customer's mill.

On-site capabilities include:

• Grinding
• Turning
• Milling
• Line boring
• Drilling
• Grooving
• Honing and finishing
• Industrial coating
• Brush plating
• Measurement and alignment
• Field balancing

On-site execution can reduce the need for:

• Component dismantling
• Heavy lifting
• Transportation
• External workshop time
• Reinstallation
• Extended production shutdowns

The maintenance work can instead be coordinated with the mill's planned shutdown.

When moving the component does not make sense, PR Rolls brings the technology to the component.

Dryer Cylinder Grinding & Coating

Restore dryer surfaces and optimise their function

Dryer cylinders are one of PR Rolls' core areas of expertise.

Cylinder surfaces gradually deteriorate through wear, corrosion, contamination and interaction with the paper web and doctoring system.

A deteriorated surface can contribute to:

• Poor paper release
• Build-up and contamination
• Increased cleaning requirements
• Unstable doctoring
• Uneven drying
• Increased draw
• Web instability
• Surface-related production problems

PR Rolls provides on-site dryer cylinder grinding and coating for paper and board machines.

Grinding restores the required cylinder geometry and surface condition. Where required, a functional coating can then be applied to provide the properties needed at the specific dryer position.

The complete process can include:

Inspection → Measurement → Grinding → Surface preparation → Functional coating → Precision finishing → Verification

The objective is to create the appropriate combination of geometry + surface condition + coating functionality.

Dryer Cylinder Surface Engineering

Different positions can require different surfaces

Not every dryer cylinder operates under identical conditions.

Surface requirements can vary according to machine position, paper or board grade, temperature, contamination, doctoring and process conditions.

Depending on the application, the required surface properties can include:

• Release
• Wear resistance
• Corrosion resistance
• Resistance to contamination
• Resistance to demanding doctoring
• Controlled surface roughness
• Long-term surface stability

PR Rolls has developed several functional coating technologies for different paper and board machine applications.

The coating should therefore not be selected simply because it has been used previously.

The surface should be selected according to what the cylinder needs to do in that particular machine position.

Dryer Section Optimisation

Look beyond an individual cylinder

Dryer section performance is not determined by one cylinder alone.

Cylinder surface condition, release, contamination, doctoring, fabrics and machine geometry can interact and influence runnability.

PR Rolls' dryer section expertise makes it possible to approach maintenance from a broader perspective.

Rather than simply asking:

“Does this cylinder need grinding?”

the more useful questions can be:

Why is the surface deteriorating?

Why is contamination occurring?

Is the surface appropriate for this position?

How does the surface interact with doctoring?

Could a different surface solution improve the application?

This turns individual cylinder maintenance into a more systematic approach to dryer section performance and component lifecycle management.

Vacuum & Suction Roll Services

Restore surfaces while protecting fabrics and suction performance

Vacuum and suction rolls operate under demanding conditions where surface wear, corrosion and contamination can affect both the roll and the machine clothing.

Worn surfaces can contribute to:

• Wire and fabric wear
• Marking
• Corrosion
• Surface damage
• Blocked suction holes
• Deteriorated roll functionality

PR Rolls provides complete on-site grinding and coating of vacuum and suction rolls for paper and board machines.

Depending on roll condition, restoration can include:

Grinding → Groove machining → Groove edge treatment → Surface preparation → HVOF coating → Non-stick treatment → Final finishing

The objective is to restore the functional surface while maintaining open suction holes and appropriate interaction between the roll and machine clothing.

On-Site Vacuum Roll Drilling & Modifications

Modify existing rolls when production requirements change
Paper and board machines evolve throughout their operating life.

Production speeds increase. Grades change. Machine clothing develops. Dewatering requirements change.

In some cases, an existing vacuum or suction roll remains mechanically suitable but its original drilling pattern no longer provides the desired open area or vacuum capacity.

PR Rolls provides on-site vacuum roll drilling and modification services that can allow existing rolls to be adapted without replacing the complete roll.

Depending on the application, this can include:

• Additional suction holes
• Modification of existing hole patterns
• Open-area optimisation
• Groove modifications
• Surface restoration
• Coating after modification

This is an example of PR Rolls' broader lifecycle philosophy:

Modify an existing component where technically appropriate instead of automatically replacing it.

Industrial Coatings for Paper & Board Machines

Engineer the surface according to its function

A roll or cylinder surface is a functional part of the production process.

Different positions require different properties.

PR Rolls provides surface engineering solutions for requirements such as:

• Release and non-stick performance
• Wear resistance
• Corrosion resistance
• Chemical resistance
• Traction
• Controlled friction
• Reduced contamination
• Resistance to doctoring
• Application-specific surface roughness

PR Rolls coating technologies include solutions such as:

TecnoClean – for release and reduced contamination.

TecnoClean CeraHybrid – a complete dryer cylinder surface concept combining grinding, coating and an optimised doctoring solution.

TecnoDiamond – a hard, wear-resistant surface for demanding applications, including dryer cylinders exposed to aggressive doctoring.

TecnoGrip – traction and anti-slip coating for winding and other positions where controlled friction is required.

TecnoGuide – corrosion-, wear- and chemical-resistant surfaces for guide rolls and demanding machine environments.

TecnoMicro - Low-Surface-Energy Coating for Headboxes & Wet-End Process Surfaces

The appropriate coating is selected according to the machine position, operating environment and required surface function.

Guide Roll Maintenance & Coating

Protect rolls operating throughout the machine

Guide rolls operate throughout paper and board machines and interact continuously with wires, felts, dryer fabrics, paper or board.

Depending on their position, they can be exposed to:

• Moisture
• Heat
• Chemicals
• Contamination
• Mechanical wear
• Fabric contact
• Corrosion

PR Rolls provides maintenance, refurbishment and surface engineering for guide rolls.

Depending on the application, services can include:

Inspection → Mechanical maintenance → Grinding → Coating → Precision finishing → Dynamic balancing

PR Rolls' TecnoGuide coating range has been developed for demanding guide roll applications where corrosion, wear and chemical resistance are important.

Spreader Rolls – Manufacturing & Refurbishment

New rolls and complete lifecycle services

Spreader rolls play an important role in controlling webs, felts and fabrics throughout paper and board production.

Correct spreading helps prevent wrinkles and contributes to stable web handling.

PR Rolls provides new spreader roll manufacturing as well as maintenance, refurbishment and modernization of existing spreader rolls.

Services can include:

• Application engineering
• New roll manufacturing
• Fixed or adjustable bow solutions
• Steel and rubber shell constructions
• Bearing and sealing maintenance
• Bow inspection and correction
• Surface restoration
• Functional coating
• Balancing

Test running

• Condition monitoring

The objective is to consider the spreader roll as a complete mechanical and functional system rather than simply replacing individual worn components.

Traction & Winding Applications

Controlled friction where grip matters

Not every paper machine surface should provide low friction.

In winding and rewinding applications, reliable traction between the web and roll surface can be essential.

Insufficient grip can contribute to:

• Web slippage
• Uneven winding
• Wrinkles
• Tracking problems
• Marking
• Inconsistent roll quality

PR Rolls provides TecnoGrip for applications requiring controlled friction and anti-slip properties.

Typical applications include:

• Winder drums
• Pope cylinders
• Reel applications
• Other rolls where controlled traction is required

Surface roughness can be selected according to the paper or board grade and application requirements.

Calender, Reel & Finishing Section Components

Precision surfaces for the final stages of production

Roll geometry and surface condition remain important after the dryer section.

Calendering, reeling and winding applications place their own requirements on surface finish, traction, geometry and rotational stability.

PR Rolls can provide maintenance and surface services for suitable:

• Calender rolls
• Reel drums
• Pope reels
• Winder drums
• Guide rolls
• Other finishing-section rolls and rotating components

Depending on the application, the required service can include grinding, coating, surface finishing, mechanical refurbishment or balancing.

MG Cylinder Services

Precision grinding, superfinishing and coating

PR Rolls also provides specialised on-site grinding, superfinishing and thermal spray coating for MG cylinders.

Continuous operation, doctoring, corrosion and wear can result in:

• Chatter marks
• Grooves
• Scratches
• Uneven wear
• Profile deviations
• Surface deterioration

PR Rolls can combine measurement, profile assessment, precision grinding, superfinishing, coating and final verification as one restoration project.

For MG cylinders, precise geometry and surface condition are particularly important because the cylinder contributes directly to the characteristic surface of machine-glazed paper.

The maintenance approach is based on the actual cylinder condition and the required final surface rather than applying a standard grinding process to every cylinder.

Measurement & Alignment

Measure first – correct what is required

Accurate measurements provide the foundation for effective paper machine maintenance.

PR Rolls provides on-site measurement and alignment services using laser measurement and precision measuring equipment.

Applications can include:

• Roll alignment
• Cylinder alignment
• Geometry measurements
• Dimensional verification
• Runout measurements
• Maintenance planning
• Verification after corrective work

Measurements can help identify wear, misalignment and dimensional deviations before unnecessary machining or component replacement is carried out.

This supports a condition-based maintenance approach:

Measure → Analyse → Correct → Verify

Field Balancing of Paper Machine Components

Correct imbalance without unnecessary component transportation

Rotating components can develop imbalance through wear, deposits, repairs, coating or other changes in mass distribution.

PR Rolls provides field balancing directly at the customer's mill for suitable rotating equipment.

Field balancing can be particularly valuable when the component is large or difficult to transport.

It can also be combined with grinding or other restoration work where both geometry and imbalance contribute to vibration.

Because vibration can have several causes, PR Rolls considers balancing together with factors such as mechanical condition, alignment and component geometry.

Workshop Maintenance & Refurbishment

Complete lifecycle services for removable rolls and cylinders

Not every component needs to be serviced in the machine.

When a roll or cylinder can be efficiently removed and transported, PR Rolls provides comprehensive workshop maintenance and refurbishment.

Depending on the component, services can include:

• Incoming inspection
• Measurement
• Disassembly
• Mechanical maintenance
• Grinding
• Surface restoration
• Functional coating
• Precision finishing
• Dynamic balancing
• Reassembly'
• Final inspection

Typical paper and board applications include:

• Guide rolls
• Support rolls
• Press rolls
• Section rolls
• Spreader rolls
• Dryer cylinders
• Other rotating components

This provides two complementary maintenance routes:

Large or difficult-to-remove component → Service on-site

Removable component → Complete workshop refurbishment

New Rolls & Cylinders

New components when refurbishment is no longer appropriate

Refurbishment can extend component life considerably, but replacement eventually becomes appropriate for some equipment.

PR Rolls can also support customers when a new roll or cylinder is required.

Through cooperation with AP-Tela Oy, new industrial rolls and cylinders can be manufactured by AP-Tela and provided with the required functional coating and precision surface finishing by PR Rolls.

PR Rolls also manufactures new spreader rolls directly as part of its spreader roll offering.

This gives paper and board mills access to both lifecycle alternatives:

Existing component → Inspect → Restore → Continue production

or

Replacement required → New component → Functional surface → Production

Planned Shutdown Services

Combine several specialist operations within one maintenance window

Paper and board mill shutdowns create a limited window for maintenance of production-critical equipment.

PR Rolls' on-site concept is designed around these situations.

Projects can combine several operations:

Measurement → Machining → Grinding → Surface preparation → Coating → Finishing → Balancing → Verification

Planning the work in advance allows equipment, personnel and methods to be prepared according to the available shutdown window.

This is particularly valuable where several large machine components require specialist work during the same outage.

Repair, Refurbish, Modernise or Replace?

Make lifecycle decisions based on component condition

A worn paper machine component does not automatically need to be replaced.

Depending on its condition and future production requirements, the appropriate strategy may be to:

Repair – correct local damage.

Grind – restore geometry and surface condition.

Recoat – create a renewed functional surface.

Refurbish – restore mechanical and surface condition.

Modernise – modify the existing component for changed production requirements.

Replace – install a new component when refurbishment is no longer appropriate.

PR Rolls' combination of on-site and workshop capabilities makes it possible to evaluate several alternatives rather than being limited to one maintenance method.

Paper Machine Component Lifecycle Management

Maintain the asset – not only the next shutdown

Large paper and board machine components can remain in production through multiple maintenance cycles.

A typical lifecycle can include:

Production → Measurement → Maintenance → Grinding → Recoating → Continued production

Later:

Refurbishment → Modernisation → Continued production

And eventually:

Condition assessment → Replacement

The objective is to preserve the component while it remains technically and economically appropriate to do so.

For cylinders in particular, this also means avoiding unnecessary material removal during repeated grinding and considering when a renewed functional coating can provide a more appropriate lifecycle solution.

Why PR Rolls for Paper & Board Mills?

Paper and board production is a core area of PR Rolls' expertise.

Our capabilities combine technologies that are often treated as separate maintenance operations:

On-site machining + Grinding + Surface engineering + Coating + Measurement + Alignment + Field balancing + Workshop refurbishment

PR Rolls currently provides specialised services for components throughout paper and board machines, including dryer cylinders, vacuum and suction rolls, guide rolls, spreader rolls, Yankee and MG cylinders, calender rolls, reel drums and other critical rotating equipment.

The objective is not simply to perform an individual grinding, machining or coating operation.

The objective is to understand what the machine component requires, select the appropriate restoration method and return it to reliable production.

Frequently Asked Questions About Paper & Board Machine Maintenance

What services does PR Rolls provide for paper and board mills?
PR Rolls provides on-site machining, grinding, coating, measurement, alignment and field balancing as well as workshop maintenance, refurbishment, dynamic balancing and new-component solutions.

Can dryer cylinders be ground and coated on-site?
Yes. PR Rolls performs dryer cylinder grinding and coating directly in paper and board machines. This can eliminate the need to remove and transport the cylinders for surface restoration.

Does PR Rolls service vacuum and suction rolls?
Yes. PR Rolls provides on-site grinding and coating of vacuum and suction rolls and can also perform drilling and modifications for suitable existing rolls.

Can PR Rolls manufacture new spreader rolls?
Yes. PR Rolls manufactures new spreader rolls and also provides maintenance, refurbishment and modernization of existing spreader rolls.

Does PR Rolls provide Yankee and MG cylinder services?
Yes. PR Rolls provides on-site grinding, profile restoration, superfinishing and coating for Yankee and MG cylinders.

Can PR Rolls improve traction on winder and reel rolls?
PR Rolls provides TecnoGrip surface technology for applications where controlled friction and anti-slip properties are required, including suitable winding and rewinding positions.

Can PR Rolls measure roll alignment?
Yes. PR Rolls provides on-site measurement and alignment using laser measurement and other precision measuring equipment.

Does PR Rolls balance paper machine rolls?
Yes. PR Rolls provides field balancing for suitable installed rotating equipment and dynamic balancing at its workshop for suitable removable components.

Can existing rolls and cylinders be refurbished instead of replaced?
In many cases, yes. The appropriate solution depends on the component's structural and mechanical condition, geometry, surface condition and future production requirements.

Can PR Rolls provide new rolls if refurbishment is no longer appropriate?
Yes. PR Rolls cooperates with AP-Tela Oy for new industrial rolls and cylinders and provides functional coating and finishing. PR Rolls also manufactures new spreader rolls.

Keep Paper & Board Machines Running

Paper and board production depends on the condition of hundreds of interacting machine components.

When surfaces deteriorate, geometry changes or rotating equipment requires maintenance, replacement is not always the first or most effective solution.

PR Rolls combines on-site machining, precision grinding, industrial coatings, measurement, alignment, balancing and workshop refurbishment to restore production-critical equipment.

From dryer cylinders and vacuum rolls to spreader rolls, guide rolls, winding equipment and other machine components, the process begins with the same questions:

What is the condition of the component?

What is causing the problem?

What surface, geometry or mechanical condition does the application require?

Can the existing component be restored or modernised for continued production?

Understand the problem → Select the right technology → Restore the component → Return to production.

Contact PR Rolls to discuss maintenance, refurbishment or surface engineering for your paper or board machine.