Innovation and quality lie at the heart of our activities.

 

We constantly monitor technological developments to improve the efficiency of paper machines and to push the limits of our covers. In addition to this we perform on-site solutions such as, coating, balancing and grinding to decrease OPEX costs.

 

Our in-house R&D laboratory is equipped to take charge of quality control during the production process. We also have the equipment and experience required for the measurement of the dynamical, mechanical, thermal, chemical and surface properties of our covers. We can optimize cover bonding resistance in the nip vs. nip load, in both wet and dry environments. Last but not east, we comply with strict industry standards and regulations. We have ISO 9001 Quality certification.

FORMING SECTION

WIRE GUIDE ROLLS / BREAST ROLLS

PAPER INDUSTRY

Wire Guide Rolls coatings are designed for the hard operating conditions found in forming section rolls. Ultra-high wear resistance for maximum life time at operations which creates the best benefits for maintenance time intervals

Manufacturing of wire guide rolls are performed with high precision and sharp tolerances with all components as full turnkey projects at our machine shop .

FORMING ROLL

As a Pioneer Project, ELKAP provided a special solution for forming rolls. With a composition of unique ceramic coating, Forming Rolls’ wear resistance, forming fabric life time and shape wearing resistance increased.

PRESS SECTION

Edge Deckles and seal strips replacement

Recovery or Replacment of the lubrication shower

Re-Coating of the Suction Roll Shell

Recovery or Replacment of the Shell and journal fittings

Complete Overhaulin of roller bearings

Recovery or Replacment of the journal/inner bearing housing set

I.D. Grinding of suction Shell to avoid I.D. Scratches

Journal grinding

Manufacturing Replacement of cap screws

Overhaul or replacement of Suction Roll front panel

before and after Comparision and dimensional inspection after maintenance service

Dynamic balancing according to ISO 1940 Class 2.5

Technical QAQC report

 

SUCTION PRESS / SUCTION PICK-UP / SUCTION COUCH ROLL

  • ELKAP Designed to eliminate shell wear with special cermet coating for outstanding wear and corrosion resistance.
  • Abrasion and corrosion resistant hard metal layers
  • Hardness 1100-1300 HV

JUMBO PRESS ROLLS

ELKAP also provides JUMBO PRESS ROLL Services

 

  • Journal repair or manufacture
  • Cap screw repair or manufacture
  • Refurbishing of worn journal intakes

ELKAP can provide  JUMBO PRESS ROLL coverings with blind holes. With our new investment our turning center has the ability to machine at C and Y axis up to 2000 mm diameter and 16.000 mm max length with 40 tons.

COUNTER SHOE PRESS ROLL

With our machining capability we can manufacture Counter Shoe Press Rolls as a full Turnkey Project including assembly, coating and balancing

DRYING SECTION

DRYER CYLINDERS

With our machining capability we can manufacture Dryer Cylinders as a full Turnkey Project including assembly, coating and balancing.

 

Also for maintenance services, ELKAP can perform changes of;

 

  • Turbulence bars
  • Rotary joints implementation
  • Bearing replacement and installation
  • On-site grinding and coating
  • Manufacturing with coating

WHY TO COAT DRYER CYLINDERS ?

 

Especially at paper manufacturing, the highest cost rate as an OPEX, belongs to ENERGY.

 

Steam consumption increases rapidly because of dip contamination on dryer cylinders. As much as this steam consumption increases, that much energy is required. To reduce the OPEX cost and improve the energy efficiency at manufacturing, our proposed coating methods bring undeniable benefits

 

Benefits:

 

  • Significantly reduction of dryer contamination
  • Reducing paper sheet tear outs
  • Reduces dusting
  • Better heat transfer rates compared to contaminated surfaces
  • Less dryer fabric wear

 

How does it work?

 

  • Non stick coating repels water, reducing surface tension
  • Non stick coating reduces ability of contaminants to adhere to cylinder surface.
  • Paper peeling force from the dryer is reduced
  • Easy doctoring off remaining dirt.

 

DOCTORABLE hard metal coating with a NONSTICK PROPERTY is applied to cylinder surface. The METAL particles are thermally melted into the surface of the tungsten-carbide layer, providing permanent dirt repelling ability.

ONSITE SERVICES (DRYING SECTION)

 

Main objective:

 

  • Improve roll shell wear resistance.
  • Protect roll body from corrosion.
  • Improved dirt repelling capacity.
  • Improve paper sheet release
  • capacity.
  • Prolong doctor blade life time.
  • Increase dryer fabric life time

SPREADER ROLLS

ELKAP provides special solutions at both manufacturing and recover of spreader rolls. With unique design for spreader rolls (including bearings, shaft and bushings) rubber - metal conversion or rubber - coated metal conversion of spreader rolls, can be designed and manufactured.  ELKAP’s spreader rolls are ideal for applications, which require high wear and temperature resistance. Segments can be manufactured with desired metal alloys, also to protect from corrosion, all surface areas can be plated with chrome or coated with special components of ceramic or carbide. Our spreader rolls can be used in many paper, tissue, board and pulp drying machine applications such as forming and press sections, calenders, coating stations, size presses, reels and winders.

 

  • Spreader roll with adjustable bow
  • Spreader roll with centrally lubricated bearings
  • Spreader roll with axle cooling

SIZING SECTION

SIZE PRESS

Ceramic coating gives the highest resistance to wear and abrasion.

 

  • Excellent chemical resistance and good corrosion resistance.
  • Longer operation time when compared to a hard rubber cover

WINDER DRUM

Winder Drums are manufactured with HVOF tungsten carbide coating in ELKAP's wokshop

 

  • Blocking slippage on the surface
  • High wear resistance
  • Good corrosion resistance
  • Long lasting roughness

Roll repairs are done with onsite grinding and coating on system.

Grinding of Press Rolls are done on our CNC roll grinding machine.

 

  • CROWNED (convex and Concave) GRINDING
  • 2400 mm Max diameter
  • 11000 mm Max Length
  • Charge Capacity up to 40 Tons

© 2019 ELKAP All Right Reserved

Contact Us:

ADRESS:

Hanlıköy Mahallesi 15. Sokak No: 21 54580

Arifiye, SAKARYA

PHONE:

+90.264.2751387

+90.264.2763355

+90.264.2769773

FAX:

+90.264.2755678

EMAIL:

elkap@elkap.com.tr

elkap@elkap.com