New Summit Lathe Roll Grinder

July 2020, Kastalon has purchased and installed a new Summit roll lathe to further enhance our large roll manufacturing and repair capabilities. Kastalon now offers the most comprehensive roller services in the industry.

The Summit lathe/roll grinder allows Kastalon to not only machine metal, but to turn, mill, groove, and grind polyurethane and rubber covered rollers to ultra-precise diameters, geometric finishes, and straightness specifications. This CNC machine has a capacity of 48 inch finished diameters x 20 feet CC (1.22 x 6.1 meters) and almost 50,000 lbs with full CNC grooving. Simple to highly complex and precise grooves and finishes can be produced with this state-of-the-art equipment.

Kastalon’s roller capacity ranges from fractional diameters and face lengths to 62 inches in diameter x 30 feet overall length (1.57 x 9.1 meters). Kastalon’s polyurethane roll coverings are available from 20 Shore A to 75 Shore D (baby’s skin soft to bowling ball hard, and anywhere in between) with surface finishes and groove patterns to optimize your roller’s performance.

We’ve combined chemistry and mechanics just for you. Contact Kastalon today and bring the Kastalon’s advantage to your operations.

What does a dead blow hammer have to do with success at a Tube Mill?

Heavy duty polyurethane Dead Blow HammerAccording to Wikipedia “A dead blow hammer is a specialized mallet helpful in minimizing damage to the struck surface and in limiting peak striking force, with minimal elastic rebound from the struck surface.”


So here is the STORY…
A tube mill’s high performance automated systems are designed to keep things moving, however, one tube mill had an issue with their pipe bouncing back too far when they impacted their adjustable pipe stop bumpers. The bumpers were designed to stop the tube and prepare them to be fed into the next area of the line.

The bouncing of tubes was causing misalignment and jams. The line then had to be shut down until the jam could be cleared. This was a continuous issue so the mill staff assumed that the hardness of the bumper needed to be adjusted, however, that was not the solution. The problem was so severe that the bumpers were causing a bounce back as far as 18 to 24” on large pipes and 8 to 12” on smaller pipes.

Fortunately, the mill contacted a representative from Kastalon to get a second opinion. Kastalon’s expertise in chemical engineering was able to determine that the hardness was not the issue, the physical and mechanical properties of the polyurethane bumper needed to be adjusted to allow the bumpers to absorb the energy rather than rebounding it. What they needed was a “dead blow bumper”.

polyurethane dead blow bumperOnce the bumpers were replaced by a proprietary Kastalon polyurethane bumper, the results were immediate and dramatic. The bounce of large pipes was reduced to 4-5 inches and the small pipes were only bouncing back about an inch.

Regardless where polyurethane is used, the secret is not just the hardness of the material, but how the material needs to work to its optimal performance in that application and environment. This is where Kastalon’s “engineered to fit” philosophy puts the emphasis on the desired result and the environment that a part is operating in. Even if it is a simple bumper!