To manufacture its products such as gypsum plasterboard, the chemical industry requires special machines that are capable of carrying out mixing and curing operations on a large scale. The feed and discharge devices are equipped with rollers that are capable of conveying the goods in both a linear direction as well as along curved sections. The use of conical rollers makes conveying in curves possible, whereby the desired curve radius can also be varied to a certain extent. Our customer, a mid-sized company, was very concerned about choosing rollers based on a particularly stable design, which should also be low maintenance. This conveyor system can create gypsum plasterboard in the course of a very specific conveyor route. The manufacturing process for these boards extends from the still viscous form of gypsum slurry to its completed curing.
Problems with the production process
The gypsum slurry is placed on a sheet with a precisely defined consistency. The reason is that for the cured gypsum plasterboard to achieve its desired strength subsequently, the gypsum slurry must be shaped and flattened after being applied. After this, the viscous gypsum compound covers a certain distance on a belt as it sets until the desired hardness has been achieved, and is then trimmed to the required dimensions. The trimmed boards are moved to a drier and stacked after drying.
The dust from the material to be processed causes a static charge in the air during the processing and drying operations. Rollers may be contaminated by the dust and their functioning impaired.
The size of the long but still flat material to be conveyed, which is still partly undergoing the curing process while being conveyed, requires a lot of sensitive handling, as it has to be conveyed in a stable form.
The time factor is important when curing gypsum
The conveying speed of the conveyor belt must be matched exactly to its length. The curing process of the gypsum compound must be completed before cutting at least to the extent that it will not disintegrate again before the cutting process. The dust that forms during the curing and drying process must not impair the functioning of the rollers prematurely.
When carrying out this customer order, the conveyor system was reconfigured for the rollers. We used special series 27 rollers in this case.
These rollers with an outer diameter of 88.9 mm have a double labyrinth seal, are suitable for very heavy conveyed items and come with splash and dust protection. The rollers were provided with a powder coating, which gives them an antistatic effect and makes them conductive. Despite these special requirements, we completed this customer order using products from our standard range. Following prior coordination and explanation by the technical department, we were able to start the extensive conversion over a period of six weeks.We do not provide our customers with any service contracts for maintenance of our rollers, as we consider these are parts subject to wear and tear. In return, we offer them contracts for preventative warehousing, which ensure short-term deliveries of new rollers in any quantity in the event of disruptions to supplies. Our customers appreciate our products very much, as they make a considerable contribution to increasing their efficiency. This means the overall performance of a conveyor and transport system is enhanced. This becomes increasingly important for systems with varied products that are in some cases associated with particular challenges.
The short-term and smooth handling of this customer order, which was associated with particular challenges, underlines once again the great flexibility, with which we can respond appropriately to complex situations at short notice. We provide our customers with ROS RollenTechnik performance to the fullest extent. This covers quoting, project management, procurement, a contract for preventative warehousing with firmly established quantities and delivery times along with coordination of delivery schedules and forwarding agents. This of course also includes special packaging, in order to avoid transport damage.
Our customers thus receive from us a complete service, whose effectiveness is also guaranteed and supported by our extensive and comprehensive warehouse system of rollers. It means we can provide our customers with maximum security from disruptions to supplies of rollers for their conveyor systems.