[Leveler Roll] Plating Repair & New Manufacturing | Shaft Build-Up Repair Using Thick Plating | Compatible with Long & Large Sizes

MICRON (THAILAND) undertakes the plating repair and new manufacturing of leveler rolls within Thailand. We provide integrated in-house processing, even for long and large sizes.

Table of Contents

• Completed in Thailand: No Need to Return to Japan, Significantly Reducing Lead Time and Costs

• Shaft Build-Up Repair Using Thick Plating

• Large Equipment Covering up to φ550×3200mm

• Strict Quality Control System and Track Record by Japanese Engineers

• Supported Specifications & Major Equipment

• Frequently Asked Questions (FAQ)

Completed in Thailand: No Need to Return to Japan, Significantly Reducing Lead Time and Costs

Leveler rolls at coil centers handling materials for stainless steel, brass, and automotive exterior parts require exceptionally high quality. Wear and scratches on these rolls are critical issues directly linked to the surface quality of the metal sheets. However, when returning them to Japan for high-precision repairs, it is not uncommon for the delivery time to take nearly half a year, including transportation and import/export procedures. In addition, the logistics costs and complicated paperwork associated with overseas shipping pose a significant burden.

We have established a system that allows us to consistently perform the entire process of base polishing, hard chrome plating, and finish polishing at our own factory in Thailand. By insourcing these processes without dispersing them to external contractors, we have realized a one-stop service completed entirely within Thailand.

With this localized system, we can significantly reduce the long downtime caused by returning items to Japan. Delivery times, which traditionally took over 6 months for a return to Japan, can be shortened to approximately 1 to 1.5 months. Securing spare rolls with a short lead time also contributes to minimizing the risk of opportunity loss due to equipment stoppages.

Shaft Build-Up Repair Using Thick Plating

The shaft section of the roll, especially the journal area where bearings are frequently attached and detached, suffers various types of damage such as deep scratches. Repairing these deep scratches is generally done by build-up welding, but we can also perform build-up repairs using thick plating. We can handle thick plating exceeding 1000 µm.

The temperature of the hard chrome plating bath is around 50 degrees Celsius. Therefore, there is almost no impact from distortion caused by internal stress, unlike welding heat. On the other hand, if there are small holes such as pinholes, we use spot inlays to minimize material loss during polishing. Since the amount of polishing is reduced, unnecessary thick plating is avoided, leading to expected cost reductions.

Large Equipment Covering up to φ550×3200mm

Processing long rolls that require extremely high surface smoothness, such as materials for automotive exterior panels, requires large equipment capable of handling their size and fine surface control technology. We are equipped with large plating baths up to 4.5m deep, as well as cylindrical grinding machines (such as TOYODA GS550-3200) compatible with long and large diameters up to φ550×3200mm. Furthermore, we have two 3-ton cranes, allowing us to consistently handle everything from the carry-in of heavy items to execution.

Through concentric processing, we precisely manage dimensions and runout in increments of 0.01 mm, while simultaneously adjusting to the surface roughness required for leveler rolls. In Thailand, there are extremely few suppliers capable of integrated processing for large rolls, and many precision rolls are sent back to Japan. With Micron Thailand, many of these can be repaired or newly procured locally. This suppresses the lead time and logistics burden associated with transportation, and contributes to reducing the risk of "scratches" and "dents" that often occur during transit.

Strict Quality Control System and Track Record by Japanese Engineers

In local repairs, a common concern among procurement personnel is the risk of rework due to variations in processing accuracy and opaque inspection standards. At our company, resident Japanese engineers with 30 years of experience in the chrome plating industry directly manage everything from establishing the work process to final inspection. To minimize subtle discrepancies in specification understanding caused by language barriers, we can correspond directly in Japanese, from initial consultations to technical meetings.

In addition, we apply inspection standards equivalent to those of factories in Japan, clarifying our quality confirmation system. This ensures we have a framework in place capable of replicating the precision and quality control concepts demanded by Japanese manufacturing sites right here in Thailand. Moreover, we have a continuous track record in repairing rolls for levelers made by Japanese manufacturers operating at coil centers in Thailand. Based on the knowledge accumulated through this track record, we respond to the required specifications for each specific site.

Supported Specifications & Major Equipment

List of Major Equipment

Frequently Asked Questions (FAQ)

Q: Can you handle rolls that are currently sent back to Japan for repair?

A: Yes. As long as drawings or the actual items are available, we can repair them within Thailand. After confirming the roll's specifications and condition, we will propose a processing method tailored to the required precision requirements, so please consult with us first.

Q: Is it possible to request only re-grinding for backup rolls?

A: Yes, it is possible. We also handle high-precision re-grinding and runout correction using cylindrical grinders for non-plated backup rolls. Please consult with us regarding the minimum diameter.

Q: Can I consult you about rolls that have exceeded their minimum diameter (wear limit)?

A: If the wear limit has been exceeded and cannot be covered by plating thickness, we will propose new manufacturing. We will consider methods suited to your requests, such as reusing the existing shaft or manufacturing from newly procured materials.

※If you would like more details, please contact our representatives directly.

• Japanese: Kobayashi +66(0)61-545-6450

• Chinese: Lin +66(0)62-467-2223

• Thai: Black +66 (0)63-206-2836