Workshop Services Industrial Coatings

Industrial Coatings

Functional coatings and surface engineering for industrial components and equipment


Industrial components operate in environments where wear, corrosion, erosion, chemicals, contamination, friction and temperature can gradually reduce performance and service life.

The right coating can do much more than protect a surface.

It can change how a component interacts with its operating environment – improving wear resistance, corrosion protection, release, traction, cleanliness, chemical resistance and other functional surface properties.

PR Rolls provides industrial coating and surface engineering solutions for a wide range of industrial components and equipment.

Applications extend beyond rolls and cylinders to components such as pumps and pump components, hydraulic components, valves, shafts, bearing areas, moulds, tools, machine parts, tanks, process equipment and other metallic surfaces.

Our objective is not simply to apply a coating.

We engineer the surface according to what the component needs to do.


Industrial Coatings Based on the Application


Start with the problem – not the coating


There is no single industrial coating that is optimal for every application.

A component suffering from abrasive wear requires different surface properties from one affected by corrosion. A roll requiring traction needs a different surface from equipment where contamination and adhesion are the main problems.

PR Rolls therefore starts by understanding:

  • What does the component do?
  • What material is it made from?
  • Why is the existing surface failing?
  • What type of wear or damage is occurring?
  • What chemicals or contaminants are present?
  • What temperatures does the component experience?
  • What friction or release properties are required?
  • What final dimensions and surface finish are needed?

Based on these factors, the appropriate coating system, surface preparation and finishing process can be selected.

Component → Operating environment → Surface challenge → Coating technology → Final functional surface


What Problems Can Industrial Coatings Solve?


Industrial coatings can be used to address several different production and maintenance challenges.

Wear
Continuous mechanical contact, abrasive materials and high loads can gradually remove material from industrial components.

Wear-resistant coatings can provide a harder functional surface and help protect the underlying component.

Corrosion
Moisture, process chemicals and aggressive operating environments can attack exposed metallic surfaces.

Protective coatings can isolate the substrate from the environment and provide improved corrosion resistance.

Erosion
High-velocity liquids, particles and process media can gradually erode component surfaces.

For suitable applications, surface engineering can provide increased resistance against the dominant erosion mechanism.

Chemical Exposure
Components used in pulp, chemical, food and other process industries can be exposed to aggressive chemicals.

The appropriate coating can provide a barrier between the component and its operating environment.

Contamination & Build-Up
Fibres, stickies, dirt, process residues and other contaminants can adhere to equipment surfaces.

Release and non-stick coatings can help reduce build-up and make surfaces easier to keep clean.

Insufficient Traction
Some industrial applications require controlled friction rather than release.

Traction coatings can create a functional surface designed to improve grip and reduce unwanted slippage.

Dimensional Wear
A component can remain mechanically sound while a local functional area becomes worn or undersized.

Suitable coating and plating technologies can restore dimensions and allow the existing component to remain in service.


Functional Surface Engineering


More than corrosion protection


Industrial coating should not be viewed simply as applying a protective layer to metal.

The coating becomes part of the component's function.

Depending on the application, PR Rolls can engineer surfaces for properties such as:

  • High wear resistance
  • Corrosion resistance
  • Chemical resistance
  • Release and non-stick performance
  • Controlled friction and traction
  • Reduced contamination
  • Easier cleaning
  • Dimensional restoration
  • Resistance to mechanical contact
  • Application-specific surface roughness

The correct result depends on the complete surface system:

Substrate condition + Surface preparation + Coating + Thickness + Final finishing = Functional surface

For this reason, PR Rolls combines coating expertise with machining, grinding and precision finishing capabilities.


Thermal Spray Coatings


High-performance surfaces for demanding industrial applications


Thermal spraying enables functional materials to be applied to an existing metallic component without manufacturing the entire component from that material.

PR Rolls uses several thermal spray technologies as part of its industrial coating solutions.

Depending on the coating system and application, these technologies can be used to create surfaces with properties such as:

  • High hardness
  • Wear resistance
  • Corrosion protection
  • Controlled friction
  • Surface durability

Carbide-based coatings are particularly relevant where high wear resistance is required.

PR Rolls' coating portfolio includes HVOF and HVAF-based solutions for demanding industrial applications.

The appropriate process is selected according to the coating material, component and required surface properties.


Wear-Resistant Industrial Coatings


Protect components exposed to demanding mechanical conditions
Wear can occur through abrasion, mechanical contact, sliding, doctoring or repeated interaction with process materials.

Instead of replacing the complete component when the surface becomes worn, a wear-resistant coating can provide a new functional surface.

Typical applications can include:

  • Industrial rolls
  • Cylinders
  • Shafts
  • Pump components
  • Valve components
  • Machine components
  • Tools
  • Other wear-exposed metallic surfaces

PR Rolls' carbide coating technologies can provide very hard, durable surfaces for demanding applications.

For particularly severe roll and cylinder applications, PR Rolls also provides TecnoDiamond, developed for high wear resistance and demanding mechanical contact.

The appropriate coating should always be selected according to the actual wear mechanism.


Corrosion & Chemical Resistant Coatings


Protect industrial components against demanding environments
Corrosion can significantly reduce component lifetime even when the component remains mechanically sound.

PR Rolls provides coating solutions for components exposed to:

  • Moisture
  • Process water
  • Chemicals
  • Humid environments
  • Corrosive contaminants
  • Other aggressive process conditions

Applications can extend beyond rolls to pump components, housings, shafts, machine structures, tanks and other process equipment.

PR Rolls' TecnoGuide range is one example of a surface technology designed to provide corrosion, wear and chemical resistance.

For higher-temperature or particularly demanding environments, the coating solution can be selected according to the actual combination of temperature, chemical exposure and mechanical wear.


Coatings for Pumps, Valves & Process Equipment


Surface protection where wear and corrosion meet


Pumps and valves often operate in environments where several deterioration mechanisms occur simultaneously.

Flowing process media can create erosion. Particles can cause abrasive wear. Chemicals can attack the substrate. Functional and sealing surfaces can gradually lose their required dimensions.

Depending on the component and application, PR Rolls can provide surface solutions for:

  • Pump components
  • Pump housings
  • Valve components
  • Shafts
  • Sleeves
  • Sealing areas
  • Process equipment
  • Other exposed metallic components

The objective can be to restore an existing surface, protect a new component or improve surface properties compared with the original solution.

This makes coating relevant both as a maintenance technology and as part of new-component manufacturing.


Coatings for Hydraulic Components


Hydraulic components require accurate dimensions and high-quality functional surfaces.

Wear, corrosion or localized damage can affect sealing and component performance even when the underlying component remains suitable for continued use.

Depending on the application, PR Rolls can combine:

Inspection → Machining → Dimensional restoration → Coating → Precision finishing

Suitable coating or plating technologies can therefore be used as part of hydraulic component refurbishment.

The feasibility and surface solution are determined according to the component material, dimensions, tolerances and operating requirements.


Coatings for Moulds & Tools


Protect and restore valuable production equipment


Industrial moulds and tools can be exposed to repeated mechanical contact, adhesion, wear, corrosion and contamination.

Replacing a complete mould or specialised tool because of local surface deterioration can be expensive and involve long lead times.

Depending on the application, PR Rolls can provide surface solutions designed to:

  • Increase wear resistance
  • Restore worn areas
  • Improve release
  • Reduce adhesion
  • Protect against corrosion
  • Restore functional dimensions
  • Extend component service life

Coating can be applied to both existing components during refurbishment and new components before they enter production.


Non-Stick & Release Coatings


Reduce adhesion and contamination


In many industrial processes, the problem is not that the surface wears too quickly – it is that material sticks to it.

Contamination and build-up can increase cleaning requirements, affect production quality and interfere with process performance.

PR Rolls provides functional surface technologies designed to reduce adhesion and improve release.

In pulp, paper and board applications, PR Rolls' TecnoClean and TecnoClean CeraHybrid technologies are examples of solutions developed around contamination, release and surface cleanliness.

PR Rolls also provides TecnoMicro for applications involving wet, hot and contamination-prone environments such as process equipment, pipework, tanks and containers.

The correct solution depends on the material contacting the surface, operating temperature, cleaning requirements and process environment.


Traction & Controlled-Friction Coatings


When the surface needs more grip – not less


Not every industrial surface should be non-stick.

Some applications depend on reliable traction between the component and the material passing over it.

PR Rolls provides TecnoGrip for applications where controlled friction and anti-slip properties are required.

The important factor is not simply to create a rough surface.

The final surface must combine the required:

Traction + Surface texture + Wear resistance + Corrosion resistance

Surface roughness and finishing can therefore be adapted according to the application.

This illustrates an important principle in PR Rolls' coating philosophy:

The correct coating is defined by the function required from the surface.


Localized Coating & Dimensional Restoration


Repair the damaged area instead of replacing the complete component


Some components do not require complete recoating.

A bearing seat, shaft, journal, sealing surface, tool or other local area may be worn or incorrectly machined while the remainder of the component remains in excellent condition.

For suitable applications, PR Rolls provides brush plating as a localized electrochemical coating and repair technology.

Brush plating can be used for applications such as:

  • Dimensional restoration
  • Bearing seats
  • Shafts and journals
  • Local wear
  • Scratches
  • Defect repair
  • Corrosion damage
  • Hydraulic components
  • Moulds and tools
  • Manufacturing and machining errors

Because the coating is applied selectively, the repair can focus on the area where material or functionality needs to be restored.

This can provide an alternative to scrapping or replacing an otherwise serviceable component.


Industrial Roll & Cylinder Coatings


Specialist surface expertise for rotating equipment


Rolls and cylinders remain an important part of PR Rolls' industrial coating expertise.

Applications include components used throughout pulp, paper and board production as well as other industrial processes.

Depending on the roll position, the required surface may need to provide:

  • Wear resistance
  • Corrosion protection
  • Release
  • Non-stick performance
  • Traction
  • Controlled roughness
  • Resistance to aggressive doctoring
  • Reduced contamination

PR Rolls has developed dedicated coating solutions for different surface requirements, including TecnoClean, TecnoClean CeraHybrid, TecnoDiamond, TecnoGrip and TecnoGuide.

The coating should be selected according to the actual process challenge rather than simply according to the type of roll.


PR Rolls Industrial Coating Solutions


Different surfaces for different problems
PR Rolls' coating portfolio includes several technologies designed around specific functional requirements.

TecnoClean
Composite surface technology for applications where release, cleanliness and reduced contamination are important.

TecnoClean CeraHybrid
A complete high-performance dryer cylinder surface concept combining surface restoration, functional coating and an optimised doctoring solution.

TecnoDiamond
Hard, wear-resistant coating technology for demanding surfaces exposed to severe mechanical wear and doctoring.

TecnoGrip
Anti-slip and traction coating for applications requiring controlled friction.

TecnoGuide
Corrosion-, wear- and chemical-resistant surface technology for guide rolls and other industrial components operating in demanding environments.

TecnoMicro
Surface technology designed to reduce contamination and build-up in wet, hot and dirty process environments.

Brush Plating
Localized electrochemical coating technology for repair, corrosion protection and dimensional restoration.

Each technology has its own application area.

PR Rolls selects the surface according to the problem that needs to be solved – not simply from a catalogue of coating materials.


Coating New Industrial Components


Surface engineering before production begins
Industrial coatings are not only a repair technology.

A new component can be provided with a functional surface before it enters production.

This allows surface properties to be engineered according to the operating environment from the beginning.

PR Rolls can coat suitable newly manufactured components such as:

  • Industrial rolls
  • Cylinders
  • Pump components
  • Valve components
  • Shafts
  • Machine components
  • Tools
  • Other metallic industrial components

For new industrial rolls and cylinders, PR Rolls also cooperates with AP-Tela Oy, combining new-component manufacturing with PR Rolls' coating and precision finishing expertise.

The objective is to consider surface performance as part of the component lifecycle from day one.


Restore, Recoat or Upgrade an Existing Component


A worn coating does not necessarily mean that the complete component needs to be replaced.

If the underlying component remains technically suitable, PR Rolls can evaluate whether the functional surface can be restored.

A typical refurbishment process can include:

Inspection → Measurement → Removal of damaged material → Machining or grinding → Surface preparation → Coating → Precision finishing → Verification

Importantly, refurbishment does not always mean reproducing the original surface.

If the previous surface suffered from recurring wear, corrosion, contamination or another failure mechanism, PR Rolls can evaluate whether a different coating technology could provide more appropriate properties.

This turns refurbishment into an opportunity to restore and potentially improve the component.


Coating as Part of a Complete Refurbishment Solution


The best result often requires more than coating


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

For this reason, PR Rolls can combine coating with other workshop capabilities such as:

  • Inspection
  • Measurement
  • Mechanical repair
  • Turning
  • Milling
  • Grinding
  • Surface preparation
  • Dimensional restoration
  • Precision finishing
  • Dynamic balancing for suitable rotating components

A worn component may therefore require several stages before the new coating is applied.

Correct substrate → Correct geometry → Correct coating → Correct final surface

This integrated approach is particularly valuable for high-value industrial components where several maintenance operations would otherwise need to be coordinated between different suppliers.


Workshop or On-Site Industrial Coating?


PR Rolls provides both workshop coating and specialised on-site coating services.

The appropriate method depends on component size, location, required surface treatment and maintenance situation.

Workshop coating
Workshop processing can be particularly suitable when:

  • The component can be removed and transported efficiently
  • Mechanical repair is also required
  • Precision machining or grinding is needed
  • Several refurbishment operations need to be combined
  • Controlled workshop processing provides the most efficient solution

On-site coating
On-site coating can be particularly valuable when:

  • The component is large or difficult to transport
  • Dismantling would create significant downtime
  • The coating can be safely and effectively applied in the installed position
  • Several large components need to be treated during a shutdown

PR Rolls has developed coating technologies specifically around the ability to perform demanding surface work directly at industrial sites.

This gives customers two complementary options:

Bring the component to PR Rolls – or bring PR Rolls' coating expertise to the component.


Industrial Coatings Across Industries


PR Rolls' surface engineering capabilities can be applied to components operating in many industrial environments.

Relevant industries include:

  • Pulp industry
  • Paper & board industry
  • Tissue industry
  • Steel & metal industry
  • Chemical industry
  • Mining industry
  • Food industry
  • Printing industry
  • Energy production
  • Marine and shipbuilding
  • Other process and manufacturing industries

Each industry creates different combinations of wear, corrosion, chemicals, contamination, temperature and mechanical loading.

The correct coating solution is therefore always application-specific.


How Do You Select the Right Industrial Coating?


Selecting an industrial coating should begin with understanding why the current surface is failing and what the new surface must accomplish.

PR Rolls considers factors such as:

Component
What is being coated and what is its function?

Substrate
What material is the component made from and what condition is it in?

Wear Mechanism
Is the dominant problem abrasion, erosion, corrosion, mechanical contact or another form of deterioration?

Environment
What temperatures, chemicals, moisture and contaminants are present?

Surface Function
Does the application require release, grip, wear resistance, corrosion protection or a combination of properties?

Geometry & Tolerances
What dimensions and surface finish must be achieved after coating?

Maintenance Strategy
Should the component be coated in the workshop or can the work be performed on-site?

The answers determine the appropriate coating system and complete repair process.

The question is therefore not simply “Which coating is hardest?”

The better question is:

“Which surface provides the properties this component actually needs?”


Why Choose PR Rolls for Industrial Coatings?


PR Rolls combines surface engineering with industrial maintenance and machining expertise.

This allows us to consider more than the coating material itself.

Depending on the project, PR Rolls can combine:

Condition assessment + Machining + Grinding + Surface preparation + Coating + Precision finishing + Balancing

Our coating expertise extends from specialised roll and cylinder surfaces to pumps, process equipment, hydraulic components, valves, moulds, tools and other industrial components.

We can also work with both existing components requiring restoration and new components requiring a functional surface before entering production.

The objective is not simply to put another layer on a component.

The objective is to create the functional surface required for reliable industrial operation.


Frequently Asked Questions About Industrial Coatings


What are industrial coatings used for?
Industrial coatings can be used to improve properties such as wear resistance, corrosion resistance, chemical resistance, release, traction, cleanliness and surface durability. They can also be used for dimensional restoration in suitable repair applications.

Does PR Rolls only coat rolls and cylinders?
No. Rolls and cylinders are an important area of PR Rolls' expertise, but coating solutions can also be applied to suitable pumps and pump components, hydraulic components, valves, shafts, moulds, tools, tanks, process equipment and other industrial components.

Can an existing component be recoated?
Yes, where the underlying component remains suitable for continued service. The existing surface and component condition should first be assessed to determine the required preparation and coating process.

Can PR Rolls coat new components?
Yes. Functional coatings can be applied to new components before they enter production. This allows the surface to be engineered according to the intended operating environment from the beginning.

Can industrial coatings restore worn dimensions?
Certain coating and plating technologies can be used for dimensional restoration. Brush plating is particularly useful for localized areas such as bearing seats, shafts, journals and other functional surfaces.

Can PR Rolls repair machining errors?
For suitable applications, yes. A localized undersized or damaged area may be restored using coating or brush plating followed by precision finishing to the required dimension.

Which industrial coating should I choose?
The appropriate coating depends on the component, substrate, operating environment and required surface properties. Wear, corrosion, chemicals, temperature, contamination, friction and required finish should all be considered before selecting a coating.

Does PR Rolls provide on-site coating?
Yes. PR Rolls provides specialised on-site coating services for suitable industrial equipment where dismantling and transportation would be inefficient. Workshop coating is also available for components that can be removed and transported.


Engineer the Surface Around the Application


Industrial coating should begin with the function of the component – not with a predefined coating.

PR Rolls provides functional coating and surface engineering solutions for new and existing industrial components, from rolls and cylinders to pumps, hydraulic components, valves, moulds, tools and process equipment.

Whether the objective is to fight wear, corrosion, erosion, contamination, adhesion or insufficient traction, the process begins by understanding the actual operating challenge.

Understand the component → Identify the surface problem → Select the coating technology → Create the functional surface

Contact PR Rolls to discuss the operating conditions of your component and determine the appropriate industrial coating solution.