Copper Shell Chill Rolls
COPPER SHELLED CHILL ROLLS HAVE THE CAPABILITY TO PRODUCE MORE PRODUCT FOR THE SAME FLOOR SPACE, USE LESS ENERGY AND SOLVE CONDENSATE PROBLEMS.
- Greatly increased line speeds
- 10 times the thermal efficiency of steel rolls
- Reduced cooling costs
- Lower energy consumption
- Elimination of condensation on roll ends
- Repeatable high quality finishes
HIGH EFFICIENCY COPPER CHILL ROLLS
BEP has more than 250 high performance copper chill rolls in circulation around the globe.
Many of the world’s leading laminators, cast film producers and high quality textured paper manufacturers have chosen to invest in our rolls because they produce higher quality products, at a greater speed, using less energy.
In 2002, we observed that our clients were unable to operate their production lines at optimum levels of performance due to the inherent limitations of both steel and aluminium chill rolls. This led us to design our first copper chill roll product.
We are experts at electroforming high quality, seamless copper tubes to any thickness our clients specify. Our unique method of manufacturing delivers the best combination of heat transfer and roll rigidity.
With coppers anti – corrosive qualities and high thermal efficiency, our rolls were a natural choice for companies who wished to increase their line speeds, improve their product quality and reduce their operating costs.
An additional unforeseen benefit of selecting copper shelled chill rolls was that our clients became able to reduce their capital expenditure on other components within their manufacturing lines.
BEP’s unique proposition allows us to replace an outer steel shell with a fine grain electroformed copper shell, up to 20mm thickness depending on the application, which we then shrink fit over stainless steel guiding spirals welded to an inner core. This provides great strength and enhanced resistance to deformation.
WHY USE COPPER?
We use copper because its thermal coefficient of heat transfer is 10 times that of steel. This means that during the time the copper shell is in contact with PE it can absorb up to 10 times more heat. This can dramatically reduce the contact time compared with steel rolls, hence allowing the line to operate at greater speeds.
CHILL ROLL COOLING ENERGY SAVINGS
Engineering experts have confirmed that for every 1°C increase in cooling water temperature, a 5% saving in energy costs can be delivered. Therefore a copper chill roll operating at 20°C can deliver the same performance as a steel roll operating at 10°C, whilst still offering you the potential to reduce your refrigeration costs by up to 50%.
Operating chill rolls at 20°C also means that in high humidity climates, condensation does not build up on the cold ends of the roll, thus reducing product waste.