Precision Roll Processing

We Guarantee Stable Production Processes for Film, Sheet Metal and Paper

We develop and produce precision roll geometries and surface structures that ensure critical production requirements and processes are met reliably and consistently in the long term.

Our particular expertise lies in the machining of precision rolls in virtually all sizes used in industry, with the tightest tolerances. This includes calender rolls, which only a few companies worldwide are capable of machining. Wilhelm Bauer is a high-end engineering partner committed to consistently high product quality and high equipment availability.

Customers are our R&D department because they constantly bring us new and specific challenges.

We grind rolls with a length of up to 10,000 millimetres.
We grind rolls with a diameter of up to 3,500 millimetres.
We process shafts, axles, extruder screws and all other rotationally symmetrical workpieces.
Our chrome tanks take workpieces up to 6,000 millimetres in total length and 2,000 millimetres in diameter.

Insights Into Our Work

Custom Roll Machining for Demanding Production Processes

Complex production requirements call for customised solutions. We create precise roll geometries and surface structures that optimise processes and drive targeted product development.

The tasks we tackle range from reducing material consumption and increasing production speed to targeted improvements in specific product properties.

We optimise roll crown geometries to ensure uniform film thickness.

Uneven film thickness across the web width can increase material usage and costs. We develop and manufacture custom roll crown geometries for rolls used in film production, tailored to the specific process conditions and the machine manufacturer’s specifications.

Through precise machining of concentricity, cylindricity and roll shape, we create the conditions for a more uniform film thickness and reduced material usage.

The result: more cost-effective film production while maintaining the same product specifications.

Custom roll geometries. Precisely manufactured. Metrologically documented.

We optimise chill rolls for higher production speeds.

As production speeds increase, reliable release of the film from the chill roll becomes critical. We adapt the roll surface to the specific requirements of the respective production process.

Through a combination of grinding, hard chrome plating and controlled matting, we create a homogeneous, precisely adjusted surface structure.

The result: higher production speeds, consistent product quality and increased output – without altering the film’s properties.

Precise chill roll surfaces for more efficient film production processes.

We develop roll surfaces to specifically enhance film properties.

With a custom-designed roll surface, specific film properties – such as printability, gloss, transparency or durability – can be further enhanced.

To achieve this, we combine and optimise existing processes to create new surface structures for rolls used in film production. Preliminary tests ensure technical feasibility and reproducibility.

The result: targeted improvements in film properties and additional quality characteristics for high-quality film products.

We develop roll surfaces specifically for the properties that make a difference in the final product.