Call Us: 01706 845960
Call Us: 01706 845960
A leading stretch film manufacturer recently encountered significant surface damage on a large chrome-plated chill roll, measuring 1.3 metres in diameter. The issue arose after a metallic object was accidentally introduced into the machine, causing a deep score mark to form around the roll’s circumference.
The company contacted Saras Process to carry out an urgent repair using our specialised on-site electroplating and metal finishing services. Thanks to our Metal on Metal process, we were able to perform the repair without removing the chill roll from the machine—saving the client valuable time and money.
We began by carefully removing all high spots left by the impact. The chrome surface was then chemically pre-treated to ensure proper adhesion for a base coat of nickel plating. Once the area was properly prepared, the scored section was filled using hard copper plating, applied with precision to restore the damaged area.
Following the plating process, we manually dressed the surface to match the original cylinder profile. Using clocks and custom cylinder gauges, we verified surface accuracy and alignment. The final stage involved applying a nickel cobalt deposit over the repaired area to create a durable, wear-resistant finish. A final hand polish restored the chill roll to its original surface condition.
All work was completed in-situ on the customer’s premises, avoiding the need for full machine disassembly or transport. This not only minimised downtime but also significantly reduced the overall cost of repair.
Thanks to our advanced selective electroplating technology and experienced engineering team, we restored the cylinder to full working order—helping the customer maintain production without disruption.
Modern web presses introduced a new challenge for our on-site electroplating team at Saras Process. The design of these advanced printing machines meant that the cylinders were only accessible from within a tunnel, positioned well above head height. This made direct access extremely difficult for our operators.
Because the Metal on Metal electroplating process involves the use of acidic and alkaline plating solutions, it was essential to find a safe and effective way to work in such restricted conditions—without compromising operator safety or the customer’s health and safety regulations.
In response, we developed a completely new electroplating method tailored specifically for high-mounted, tunnel-access cylinder repairs. This innovative approach allowed our technicians to perform metal finishing work safely from below the cylinders, ensuring clean application and full containment of chemicals in a confined environment.
In addition to updating our repair technique, we engineered a lightweight, compact switch-mode power supply, designed to support on-site electroplating in these space-limited conditions. This smaller rectifier not only offered full plating performance but also gave our team greater mobility and precision when navigating tight workspaces within the press.
These innovations allowed us to carry out complex printing cylinder repairs on-site—efficiently, safely, and without the need to dismantle machinery or remove cylinders. It’s another example of how Saras Process adapts our electroplating equipment and expertise to meet real-world engineering challenges.