Basic Sugar Mill Roller

Product Name

Basic Sugar Mill Roller

Purpose

The Basic Sugar Mill Roller delivers reliable, high-load crushing performance for primary juice extraction operations. Its primary purpose is to tightly grip, compress, and process the cane blanket. It guarantees optimal juice extraction rates and ensures maximum service life under severe operational conditions. 

Suitable Positions & Configurations for Basic Sugar Mill Rollers 

The Basic Sugar Mill Roller provides crucial service in the following configurations and positions:

• Mill Type Configurations:
  • 3-Roller Mills
  • 5-Roller Mills
  • 6-Roller Tandem Configurations
• Mill Stand Positions:
  • Top Roll: Provides the main crushing force.
  • Feed Roll / Front Roll: Essential for gripping the cane blanket and ensuring consistent, controlled delivery.
  • Discharge Roll / Back Roll: Critical for final dewatering and bagasse expulsion.

Basic Sugar Mill Roller Material

The basic sugar mill roller uses a custom casting material shell with a forged steel shaft core. This combination ensures a balance of exceptional surface hardness for wear resistance and superior core strength to handle immense operational torque and bending moments.

Basic Sugar Mill Roller Material – Casting and Forging

Shell: Specialized Custom Casting Material

• Composition Focus: High-Carbon, High-Chrome alloy formulation designed specifically for abrasive, high-pressure service in the cane crushing environment.
• Key Feature: Delivers exceptional Wear Resistance that far surpasses standard iron rolls.
• Guaranteed Surface Hardness: Typically maintained within the range of 450-550 BHN. This hardness range is the optimal balance between abrasion resistance and resistance to spalling/chipping.
• Operational Enhancement: The shell incorporates an optimized standard grooving profile with specific Sugar Mill Roller Arcing. This geometry is precisely calibrated to maximize the cane blanket grip and ensure a consistent, reliable feed, directly solving the problem of Inconsistent Cane Feeding and Sub-optimal Milling.

Shaft: Durable Forged Steel Roller Shaft

• Core Component: The central core is a critical component manufactured from high-grade Forged Steel. Forging ensures a non-porous, homogeneous grain structure free from internal defects.
• Material Standard: Typically high-tensile carbon or low-alloy steel (e.g., AISI 1045 or equivalent).
• Fusion Integrity: The shell is seamlessly fused to the forged steel shaft, eliminating the risk of movement or separation under extreme load conditions.

Basic Sugar Mill Roller Heat Treatment

Forged Steel Roller Shaft

• Process: The forged shaft undergoes a meticulous thermal cycle, typically involving Quenching and Tempering (Q&T).
• Objective: To achieve the required mechanical properties: high tensile strength, excellent yield strength, and impact resistance. This strengthens the critical Core Component against fatigue failure and bending stress.

Custom Casting Material Shell

• Process: A specific cooling rate and post-casting heat stabilization are applied to optimize the carbide distribution and ensure the target surface hardness of 450-550 BHN is consistently achieved across the entire working surface. This thermal management is vital for the roll’s longevity.

Key Dimensions – Diameter and Length, Tolerance, Weight

Standard Sugar Mill Roller Sizes

We guarantee zero Fitment Issues by adhering strictly to international Standard specifications for all dimensions.

Basic Sugar Mill Roller’s Precision Machining Tolerance

A fine machining tolerance e.g 0.1mm is applied to all critical surfaces (journal, flange, and bore) to ensure a perfect fit with existing mill components and bearings, eliminating costly field adjustments.

Inspection & Quality

Quality

Our commitment is to deliver High Quality and competitive Sugar Mill Roller Prices without compromise on performance. Quality is maintained through a process-oriented system focused on:

• Material Traceability: 100% traceability from raw material procurement to final shipment.
• Structural Integrity: Non-Destructive Testing (NDT), including Ultrasonic Testing (UT) of the shaft and shell fusion zone, to detect any sub-surface defects.
• Dimensional Accuracy: Comprehensive 3D coordinate measurement of all critical dimensions and geometric tolerances.

QA/QC Inspectors

Our quality assurance process is overseen by stringent, certified QA/QC Inspectors who follow internationally recognized standards (e.g., ISO 9001). They monitor every stage, from casting pour temperature to final groove machining and balancing.

Machinery Test Report

Every Basic Sugar Mill Roller is delivered with a comprehensive technical documentation package, including:

• Material Composition Report: Chemical analysis of both the shell casting and forged shaft.
• Hardness Certification: Guaranteed surface hardness measurement results.
• Dimensional Inspection Report: Detailed record of all key dimensions and adherence to tolerance.
• NDT Report: Results of Ultrasonic and Magnetic Particle Inspection (MPI).

Customizable Designs

While the Basic Sugar Mill Roller features an optimized standard profile, we offer flexibility for future needs:

• Groove Profile: Customization of pitch, depth, and angle.
• Journal Design: Adaptations for specific bearing housing requirements.