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Roll Inspection
After a roll is received, it gets completely inspected. The core and shaft are UT / Mag tested if required. All journal and core diameters are noted. The condition of the cover along with its size and general appearance are noted. Any bearings, couplings and gears that are on the roll are either removed and logged or left on the roll if it does not interfere with covering.
Roll Prep
After incoming inspection, the roll is stripped of old covering. The roll body is completely cleaned of old material and residue. The roll is then steel shot blasted to produce a bondable surface. This surface is then thoroughly degreased. Then an adhesive is applied in two coats to enable urethane to metal bonding.
Casting
The roll is baked for six to eight hours to enable the adhesive to bond to the steel and activate for urethane bonding. A mold is placed around the core, which is slightly oversized from the diameter, and sealed into place. Urethane is poured from a very sophisticated metering/measuring machine. This machine ensures proper mix, no air bubbles and a uniform mix. Once the mold is full, the roll is post cured for up to eight hours.
Finishing
The cast roll is now sent to a finishing department. The roll is machined down to the diameter and face width ordered by our customer. Any grooving or crowning is completed in this area. All surface finishes are also applied in this area. Very tight tolerances and surface finishes are required by some industries.
Final Inspection
After the roll is complete, every diameter is double checked and recorded. The durometer, size, runout, and taper are all noted and checked to our customer’s specifications and order. The journals are rechecked. The balance of the roll is rechecked. Everything is noted and stored with the record of this roll. The roll is now finished and ready to be returned.
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Part design
A custom molded part can be made from an existing part, a print, or a sketch. Once the professionals at Universal Urethane Products have the information we need, we send a detailed quote for the parts and any tooling needed to produce the part. Once a mold is made, the parts durometer (hardness) and color can be changed with no added tooling costs. Tooling costs are very inexpensive for custom molding. We also store and maintain your mold for future orders.
Part manufacturing
Custom molded parts are made in our compression molding department. We pour our material into the cavity of the mold, place the mold in the compression press, and then squeeze the mold under heat and pressure to form your custom part. After a short period of time, the part is demolded and post cured. Once we have a mold for your parts, making parts is very simple. Should an emergency arise, we would make parts the same day as ordered for possible shipment the next day.
Part finishing
Parts that have been made and postcured need to be cleaned and inspected. We take all of our custom parts to a deflashing area where the mold flashing is removed. The parts are then inspected for voids and other visual defects. They are spot checked against your print or sketch for size, durometer, color and general appearance. The parts are then shipped to you. |
Rolls are either received by commercial freight or by our own fleet of trucks, which covers an extensive area across the Midwest and beyond. Our quality procedure starts with an incoming inspection of the roll. This inspection includes reviewing a checklist which when completed is affixed to the roll. Any necessary core or journal repairs are reported to the customer. Once approved, these repairs are economically completed in our in-house machine shop. 
