February 16, 2022

Bad rollers make all the difference.

Sometimes it’s wondering why your scrap ratio or machine downtime is higher than it should be.
Sometimes it’s as easy as visibly seeing the rubber fail in your production process.
  • Sometimes it isn’t as obvious.

Let me tell you a story about how Alrol’s unique expertise helped identify and solved extended machine downtime and short life of rollers.

A new customer who had found Alrol from our website approached me. Since the company is nearby, the roller was brought to us and the Director of Operations asked me what the reason for all these ‘cuts’ on the rubber surface would be.
Since 2003, Alrol of America has seen similar issues with many of our customers’ rollers. Though in a conversation where I asked a series of questions I determined the root cause of this issue. 
  • In that conversation I got to know the company’s situation better.
  • Their OEM from overseas sold them rollers with a covering which is chemically attacked by a process agent the company uses.
Once discussing these issues with the Alrol Team, we came up with switching to a rubber material which resists the chemicals used in the production process.

Once discussing these issues with the Alrol team, we came up with switching to a rubber material which resists the chemicals used in the production process. This is one of the many times we’ve been able to use our experience and knowledge to help our customers. 

A process agent chemically destroyed that rubber covering. 

Are your rollers just not performing well?

The entire ‘picture’ needs to be looked at with knowledge and experience.

Email me: andreas@alrolusa.com


Alrol has the know how that makes us experts.

We look at the whole topic through our customer’s eyes.



Longer running rollers lower the production costs and reduce the machine down-time.

Our products and services cover your needs and exceed your expectations.

The story above ended with one happy customer:
  • The rollers lasted much longer.
  • The machine down time was reduced to a ‘normal’ maintenance cycle.
It’s one of the many times we’ve been able to use our experience and knowledge to help our customers.
Call me today at 706 260 1315.
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October 28, 2021

rubber roller different rubbers

High scrap ratios and low production rates adds substantially to the production costs.

Scrap Ratio affects the Production costs – a definition

One way to keep your production costs low – and your profitability high – is to take care about your scrap rate. Scrap rates measure the failed assemblies or production of an output product which cannot be restored in relation to the total. Reasons for scrapping can be exemplary poor raw or input materials, careless set up procedures, faulty machinery or ineffective production operators.

As a consequence, you might not produce enough goods to fulfill all customer orders and lose sales volume. Through checking on high scrap rates certain product or production group production managers can try to find the root causes for it and take the respective measures to overcome the negative impact. (Iris Zimmermann)

What Causes Scrap and Rework in Manufacturing?

Scrap is a byproduct of an inefficient process. Causes can vary, including:

Machine malfunction
Can be caused by failing rollers
Poor quality materials
Low rubber quality on rollers
Human error
Design changes not communicated
Design changes not implemented
Lack of a quality assurance program

These items are controllable and in most cases, preventable with the right processes, systems, and training. 
The costs associated with poor quality products are high.
Every time that you produce scrap or have to rework parts, you’re increasing the cost of production.

Investing in improving your performance to reduce scrap can significantly lower the cost of producing parts and increase your profit margin. (Bluestreak)

To be continued ….

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April 12, 2020

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