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Carbide Rolls are Non-Magnetic
I have been using non-magnetic carbide rolls from Roll-Kraft in the operation at Middletown Tube Works for the past ten years. We like using this product for our weld rolls because of its non magnetic properties and durability. The non-magnetic carbide rolls from Roll Kraft don't heat up as much as regular tool steel and this helps us to limit our use of weld roll cooling. We also use this product in the sizing section to stop weld seam grooving and in other wear areas. Non-magnetic carbide rolls from Roll Kraft help to ensure that we continue to produce high quality tubing.
Duane Sulski
Corporate Engineer
Middletown Tube Works
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Welded Tube Orwell on Carbide
At Welded Tubes, carbide inserted mill rolls were the only rational and logical choice for our high volume runners. Carbide has reduced our need for frequent and costly regrinds and gives us the opportunity to keep the tooling in house where it is needed. We are seeing about ten times more than our normal expected tool life before needing any regrind attention. The surface quality is immensely improved by the reduced friction given from carbide as opposed to the standard D-2 roll. The reduced friction helps to eliminate roll marks for our plating critical customers. Carbide inserted mill tooling has helped us in many ways to ensure our customers are happy with the quality of product we have supplied them and keeping the customers happy is what keeps our shop doors open.
Kevin Barker
Plant Manager
Welded Tubes, Inc.
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Tungsten Carbide Cost Justification
We went from two regrinds a year on a set of D2 tooling to no reworks for six years running the carbide tooling, and we reduced marking on the tube. We typically run (4) four million feet of this product per year so the savings and benefits have paid for the carbide many times over.
Kelvin Egner
Tube Mill Production Manager
Shelby Welded Tube
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Cost Justification for Tungsten Carbide Rolls vs. Split & Bolted
From the first day that I started working at Ameristar Fence, I knew I had to keep track of wear and tear of our tooling in our facility as I had done in the past at Wheatland Tube, after a period of time I set our tolerances at 2,000 tons of maximum production on 1.315 and 1.660 O.D. tooling, and at 3,000 tons on larger tooling sets 1.900 to 2.875, which happened to be pretty much the same as my past experience at Wheatland Tube…after a period of time the topic of carbide tooling was brought up during a meeting in which I stated that in my past experience with my former employer it had given us great results with longer production time and less reworks, saving rework and shipping costs; after our meeting I assured my boss that it would serve us greatly with production and cost saving measures, so I was given the green light to “try” a set of carbide tooling…after this “trial” I am very happy to share our results with the tubing industry…after acquisition of a 1.660 tooling set in August 2006, which still has not been reworked as of May of 2008, the output of this particular tooling set has reached 9,256 tons (an increase of more than 300% in production) with no sizing problems as of yet and very minimal or no roll marks during production as well, while at the same time keeping galv build up to a minimum or none whatsoever in some cases, therefore making it safer for our operators by keeping their hands out of harms way by removing build up during production (on tooling)...after the success of our trial with 1.660 tooling I was given the green light to order a 2.017 sq. tooling set, maximum production on D-2 steel was set at 500 to 600 tons, after we started production with our carbide tooling, our first rework took part after 3147 tons on that particular tooling set, which if you do the math, well, the results pretty much speak for themselves; as impressive as these results were, the biggest savings we made were with our acquisition of our .590 Sq. carbide tooling set, we had been producing tube with split and bolted D-2 steel tooling which had to be reworked after 3.5 to 4 million feet, after production with carbide inserted tooling took place, our first rework of our carbide tooling took place after 53,000,000 feet, this alone saved us 13 reworks which would have been done with D-2 steel tooling, so, after seeing the results we get out of D-2 steel vs. Carbide inserted tooling, the decision was simple to slowly move over to carbide as tooling sets’ lifespan wears out, our inventory now includes 6 sets of carbide inserted tooling with 2 more due in house within 3 months, as good a result as D-2 steel has given us, carbide inserted tooling by far has the best results bar none.
Jorge Palma
Tool Room Tech.
Ameristar Fence Products.
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Great Seminar and Key Performance Manual
Many times I have been to seminars presented by engaging well-informed speakers who had an answer for every situation. I would leave feeling I had all the answers and all my frustration and anxiety over the process or equipment had been relieved. Once back on the plant floor and in the real world I would soon learn that everything did not line up with the speakers perfect world and I felt I had wasted valuable time with little to show for it.
After a week of applying what I learned I have to say this was not the case with the Roll Kraft seminar. The speakers were engaging and more than well informed. The minute I walked back onto the plant floor I had my very detailed and easy to use seminar manual open and applying what I had learned.
Every question I had was answered thoroughly and I found in most cases my concerns were similar to the other attendees and there was a methodical and documented procedure to handle the situation. Roll Kraft took a machine that at times could be overwhelming and complex and hour by hour broke it down into a process that just made sense.
Both Robert and Bret are at the top of their game. The difference for me was that they not only knew forming mill process but they new in detail every brand of mill that was represented and compared the similarities and the differences. Rather than explain how a mill will work when tooling, coil and pm are all they helped me to understand when (which is most of the time) all these do not line up how to make a quality product. In the long term they presented a pm procedure that will insure the mill is operating, as it should. I feel I have gained a lifetime of experience in one 8-hour class. Because everything I learned follows the seminar manual presented I never have to worry about forgetting some key information that was passed along it is documented.
Kevin L. Goad
Handle Operations Manager
The Libman Company
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Great Job Great Service
“I am the maintenance supervisor for Paris Metal Products. We were in need of repairing and replacing our roll sets on our roll former. I knew they were in poor shape but needed to keep the cost of repair down as much as possible. After talking to a ROLL-KRAFT tec Shawn Mitchell he was able to give me three options after inspection. We decided on option #2 this option required some new sets and repair of the rest. The turn over time was excellent and quality of work outstanding. The reassembly went without a hitch and was one of the smoothest ones I have done. I would recommend their service to any manufacturer with roll forming operations.”
Kerry Littletown
Maintenance Supervisor
Paris Metal Products
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Superior Service
“We used the on-site technical services in the installation and set up of a complete used roll forming line. Their personnel were experienced, hard working and very detail oriented. Their approach was systematic and structured to identify and resolve each installation and operational issue. They had the full support of the team of technicians at Roll Kraft. We were very pleased with the services we utilized.”
John
Midwest Steel & Tube
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Excellent Customer Service
Our experience with Roll-Kraft is that it is a good quality and reliable Company. The engineering is top of the line. The company offers excellent customer service as well.
When we ordered our first tooling with Roll-Kraft we simply sent them a finished sample of the product along with the drawings of the tooling and they were able to efficiently engineer a quality tooling set with minimal questions.
Our experience with Roll-Kraft has always been a positive one.
Salvador Carranza
Air Louvers/Samson Products
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Knowledgeable & Professional Staff
Roll-Kraft offers unparalleled technical support for our tube mills. Both class room and on site training have increased operator confidence and removed some of the mystery of tube mill operations. Roll-Kraft's technical notes have become the standard of instruction for our mill operators and engineering staff. Roll-Kraft provides rapid response to quotations, technical questions and replacement parts. Every shipment has been on time and every phone call has been handled by courteous, knowledgeable and professional staff. Roll-Kraft has earned the right to be our supplier of choice for mill tooling at all of our facilities worldwide.
Randall Bradley
Director, Manufacturing Engineering
Evapco Corporation
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Great Rolls and Prompt Service
Hi Ovidiu,
Everything is fine, I received the reconditioned rolls yesterday and it sure did relieve the pressure that we were faced with. Thanks for your prompt and efficient service, Gary also said to let you know that your efforts to help us out was greatly appreciated by him and it is good to know that we are dealing an excellent service provider.
Cored Wire Dept. Manager,
Lincoln Electric Co. Canada
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Tooling Optimization
Joe McGee phoned to say their customer was very impressed with the way we handled a situation they had. Their customer needed some adjustments to the tooling we provided. Bret was visiting at the time and immediately contacted the Roll-Kraft engineers to revise the design and get the tooling they needed. This was a new part for this customer and they needed production at a high volume. Joe said, They didn't want to take a chance with someone else, and, they felt comfortable with Roll-Kraft. Within a few days the re-designed tooling was on-site and doing its job.
Joe McGee
Lock Joint Tube
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Regrinds at Their Best
Tom Gerken from Boyce Industries in Chicago called to say they finally setup the new reshape tooling we manufactured at Roll-Kraft and ran production last week says the reshape tooling worked out very well and mentioned the first part out of the Ardcor F-10 machine was acceptable. Tom just wanted to call and let us know we did a great job. Great job guys!!
Tom Gerken
Boyce Industries
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Fantastic Roll Former
“John, here is a photo of the machines, now finished as I said I would send to you. I am very impressed by the quality of your roll-formers.”
Bruce Overgard
Balance Systems, Inc.
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Excellent Sales Representatives
Hello Soonarie,
I received the rolls yesterday. You have been nothing but helpful and this was the best roll buying experience I have ever been involved in. Thank you very much for your help and efforts!
I will definitely be talking to you in the future.
Israel
Century Tube Corporation
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Excellent Service
To Roll-Kraft
Thank you all very much for the prompt service! Plus Thank you very much for the phone call this pm confirming UPS overnight shipment / letting me know replacement roll was in-house. Tracked it down and just finished installation - its looking fine and we are back in business. Thanks again for the excellent service!
David Brigl
Raynor Garage Doors
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