Our Corrosion-Resistant Chill Rolls Helped a North America 8.7m BOPP Film Producer Reduce Roller Procurement Costs by Over 50%

Customer Profile

Industry: BOPP Film Manufacturing
Location: North America
Production Line Width: 8.7 meters
Application: 450m/min  BOPP Film Production

The Challenge

A leading north America BOPP film manufacturer operating an 8.7-meter production line had long relied on conventional chrome-plated chill rolls. Although these rolls initially provided acceptable cooling performance, they presented several long-term challenges:

• Chrome plating gradually wore out under continuous operation.
• Surface corrosion affected film quality and roll performance.
• Frequent refurbishment and replacement increased maintenance costs.
• Unexpected downtime reduced production efficiency.
• The total cost of ownership continued to rise.

The customer was looking for a more durable solution that could withstand continuous production while reducing lifecycle costs.

Our Solution

After evaluating the customer’s operating conditions, our engineering team recommended replacing the traditional chrome-plated chill rolls with our corrosion-resistant chill rolls.

The customized solution included:

• Advanced corrosion-resistant roll surface technology
• High-precision dynamic balancing for high-speed operation
• Uniform internal cooling channel design
• Superior temperature uniformity across the full 8.7-meter width
• Long-service-life construction designed for continuous industrial production

The new rolls were installed without requiring major modifications to the existing production line.

Results

Following implementation, the customer achieved significant operational improvements.

More Than 50% Reduction in Roller Procurement Costs

The extended service life of our corrosion-resistant chill rolls dramatically reduced the frequency of replacement and refurbishment. Over the equipment lifecycle, roller procurement costs were reduced by more than 50%.

Longer Service Life

Compared with conventional chrome-plated rolls, the corrosion-resistant surface maintained excellent cooling performance and surface quality for a much longer period, even under demanding operating conditions.

Reduced Maintenance and Downtime

The improved durability minimized maintenance intervals and shortened production interruptions, allowing the customer to maintain higher equipment availability.

Increased BOPP Film Output

With fewer shutdowns and stable cooling performance, the production line operated more consistently, improving overall production efficiency and increasing BOPP film output.

Key Benefits

• Over 50% lower roller procurement costs
• Significantly longer roller service life
• Reduced maintenance frequency
• Less production downtime
• Stable cooling performance
• Improved BOPP film productivity
• Lower total cost of ownership (TCO)

Customer Value

For large-width BOPP production lines, roller reliability directly impacts production efficiency and operating costs. By upgrading from traditional chrome-plated chill rolls to our corrosion-resistant solution, the customer not only reduced procurement expenses but also achieved higher line availability, longer maintenance intervals, and improved production capacity.