Vail Technical and Mechanical Services: anticipating and responding to your roll cover demands.Vail treats each customer uniquely with custom formulations and designsIn our 100 years of making roll covers, we have yet to find any two customers whose processes, equipment, environment, and employees are exactly the same. At Vail, we always look at your unique situation, so we can customize products and services to help improve your operations and reduce your total costs of production. We Offer:
Vail Rubber can help you choose the correct roll cover, cover finishes, and cover profiles for your application by:
The Vail technical services team has extensive experience in formulating cover materials. With our formulation ability and our own mixing facility, we can meet specific application needs and also ensure that the product meets our stringent quality requirements. ReGrind or recover: RETURN YOUR ROLLS TO LIKE-NEW CONDITIONAt Vail we treat each used roll cover that is able to be reground with the same care as we do a new recover. Such attention to detail ensures that a refurbished cover returns to your line ready to perform at peak efficiency. Regrinding of roll covers means faster turnarounds than a complete recover. Vail works with every customer to maximize cover life that will save you money. When recovering is required, a new Vail cover can lead to additional cost savings, because Vail designed cover materials often better withstand the speed, loadings, abrasion and chemicals that contribute to your roll cover's premature wearing and damage. Our team has the ability to provide precise dimensions on roll covers. For some applications, less stringent cover dimensional tolerances will still allow the cover to function properly and can save you money on your roll cover price. For more critical applications, tight tolerances are often required to function properly, which typically results in a more costly cover. HARDNESS: COMPRESSION/DEFLECTION CHARACTERISTICSVail makes a full range of roll covers that range in hardness from bone hard to very soft. Elastomer hardness is determined by its resistance to compression. These compression characteristics help determine the width of the nip in nipped rolls. The width of the nip influences two critical factors: (1) How long the material passing through the nip is under pressure and (2) the firmness of the contact between the roller cover and the material being processed. Two types of gauges are commonly used to measure hardness (Shore A or D gauges, or a Pusey & Jones plastometer (P&J))
Standard durometer hardness tolerances are +/-5 durometer points. P&J hardness tolerances vary with the P&J hardness specification. There is not a direct correlation between Shore A and D gauges, and the P & J gauge. Please contact Vail with your questions about hardness guidelines or about which hardness system to use. ROLL COVERING FINISHES: DESIGNED TO OPTIMIZE PROCESS RESULTS AND SATISFACTIONWhen we analyze the type of cover finish required on your covers, we consider many factors such as: operating speeds, loading, the characteristics of your end product and the hardness of your cover material. Some of our standard finish options for polyurethane and rubber roll covers include:
PRECISION GROOVING & BEVELING: DESIGNS TO IMPROVE PAPER, METAL, AND INDUSTRIAL PROCESSING
DRILL CLEANING AND DRILLING NEW COVERSPrecision Drilling. Our Multi-Spindle Roll Drill can drill new covers to your specified patterns and clean plugged cores and shells efficiently and thoroughly. Used primarily in paper mill wet applications, these drill designs are made to draw off liquids from the wet paper sheet. Vail roll covers perform in some of the most challenging wet applications in the paper industry. Drilling is the surest way to put your Vail Drill Press – or Vail Press – roll-covers back on line with minimal downtime and expense. INSPECTION SERVICES: FROM COVER SURFACE TO COREWhen your roll arrives at Vail, our production/technical team can inspect both the roll cover and core for defects or special problems. Inspection of the core generally includes run out checks, visual inspection, bearing and seal surface inspection, and ultrasound and magnetic particle testing. Vail is also set up to do inspection of bearings, seals and couplings. Inspection of the cover includes visual inspection, and inspection of cover properties. After the inspection, we report back to the customer concerning how we can bring the cover and core back to blueprint specifications. METAL CORE REPAIR/MILLWRIGHT SERVICESFewer and fewer mills are relying on their own in-house millwright and core repair services, deciding instead to outsource these services to Vail and save with one-stop shopping. Vail's century of advancing roll cover technology extends into our roll mechanical services. We control the turnaround time, design, workmanship and quality of these repairs at our facility. Vail can rebuild the core, or construct a new one, disassemble the bearings, repair bearing surfaces, replace bearings, seals and couplings or whatever is needed to bring your core back to blueprint specifications. At Vail, our goal is to provide quality core repairs and millwright services that will give the best overall value to you the customer. VAIL'S REBUILDING AND RECONDITIONING of SUCTION BOXES SAVES TIME AND MONEYIn addition to precisely drilling roll covers, Vail can also conduct complete inspections of your suction box components including bearing inspection and replacement; seal strip, end deckle, grease line, and shower replacement. While Vail has hundreds of processing heads available, we are also able if needed to custom machine one to fit your shell dimensions. NEW ROLL CORES: BUILT TO YOUR ENGINEERING DRAWINGS OR SPECIFICATIONSContact us with your drawings or design requirements. DELIVERY SERVICES: VAIL OFTEN REPAIRS AND DELIVERS IN THE TIME OTHERS DESIGNATE AS "RUSH" SERVICESVail services companies anywhere in the continental United States and some provinces of Canada. We operate our own fleet of trucks to expedite transporting rolls to our customers in the Midwest. If your facilities are located more than 400 miles from our St. Joseph, Mich. headquarters, your roll may be shipped by common carrier. Rush deliveries are available to support your processes. Talk to us about how we can improve your roll cover turnaround time and satisfaction. |
Vail Rubber is an American company that has been owned and operated by the descendants of William A. Vail for more than 100 years (