In industrial manufacturing, every mechanical component must perform flawlessly to ensure the production line operates smoothly. A recent project by Sterling Impreglon Asia demonstrated how our Brush Plating technology helped restore a calendar roll used in the production of Polypropylene (PP) sheets and blocks, breathing new life into this critical asset.

The Challenge: Calendar Roll Wear and Tear

Calendar rolls are essential to the transformation of raw materials into finished products. They apply continuous heat and pressure to create uniform thickness, density, and smoothness in materials like Polypropylene sheets. Over time, these rolls endure significant wear and tear, leading to performance issues that compromise product quality. Our task was to restore a worn calendar roll back to its original precision and functionality.

The Restoration Process

At Sterling Impreglon Asia, we specialize in advanced repair techniques using our proprietary Brush Plating process. For this calendar roll, we executed a detailed restoration process that included the following key steps:

1. Assessing Damage and Preparation: We began by grinding open the damaged areas of the roll, ensuring that the affected sections were properly prepared for repair while maintaining the structural integrity of the component.

2. Brush Plating Application: Using our Brush Copper Plating technique, we rebuilt the worn surfaces. This method provides the exact control needed to restore the roll to its original dimensions, ensuring durability and optimal performance in the production process.

3. Smoothing and Polishing: After the Brush Plating process, we meticulously blended the plated sections to match the roll’s original surface, ensuring seamless operation. The roll then underwent a final polishing to achieve the high-quality finish required for precision production.

4. Nickel Capping: To complete the restoration, we applied a nickel capping layer, enhancing both the structural integrity and aesthetic appeal of the calendar roll.



The Result: Performance Restored

After our precision restoration, the calendar roll was fully restored to its original condition. It was once again ready to deliver consistent and high-quality results in the production of Polypropylene (PP) sheets and blocks. This restoration not only extended the lifespan of the roll but also contributed to reducing downtime and improving overall manufacturing efficiency.

At Sterling Impreglon Asia, our advanced Brush Plating technology allows us to restore critical mechanical components to their optimal condition, ensuring longevity and performance.