A PREMIUM SUGAR MILL ROLLER SHELL MATERIAL FOR CONVENTIONAL AND HIGH PERFORMANCE INTERNAL BLEEDING ROLLERS

HISTORICALLY, SUGAR MILL roller shells have been manufactured in open grained cast iron for a number of reasons. Open grain cast iron provides the rough surface conducive to better traction. Cast iron has low elongation so that the roller teeth tend to break under high, concentrated loads, possibly saving other, more serious, extensive damage. The traditional cast iron shells are also low cost compared to more sophisticated materials. Cast iron however, suffers from low strength and low weldability. With the advent of surface engineered rollers by weld deposition (hardfacing), the benefit of the rough surface of the cast iron needed to be viewed in different light and for better extraction a more efficient, stronger, wear resistant, weldable shell material was a necessity. This paper explores the alternative material, ‘SBR alloy’, a cast iron alloy, which has benefits of open grain cast iron, but has higher strength, excellent weldability along with higher wear and corrosion resistance. Internal bleeding rollers have been in manufacture since 1978 as perceived by Mr. Jean Bouvet. However, the basic design suffered from many shortcomings. S. B. Reshellers Pvt. Ltd., after considerable research and development and various geometries, has patented a design proven to be highly efficient, known as ‘Kamal’ rollers. This paper discusses the operation of internal bleeding Kamal rollers and the benefits of using them in SBR alloy.