Copper chill rolls

Copper-shelled heat transfer rolls have the capability to produce more product for the same floor space, use less energy, and solve condensate problems.

The world's best manufacturers have moved to copper chill rolls

Many of the world’s leading laminators, cast film producers and high quality textured paper manufacturers have chosen to invest in our rolls because they produce higher quality products, at greater speed, using less energy.

In 2002, we observed that our clients were unable to operate their production lines at optimum levels of performance due to the inherent limitations of both steel and aluminium chill rolls. This led us to design our first copper chill roll product.

We are experts at electroforming high quality, seamless copper tubes to any thickness our clients specify. Our unique method of manufacture delivers the best combination of heat transfer and roll rigidity. With copper’s anti–corrosive qualities and high-thermal efficiency, our rolls were a natural choice for companies wishing to increase their line speeds, improve their product quality and reduce their operating costs.

An additional unforeseen benefit of selecting copper-shelled chill rolls is that our clients have been able to reduce their capital expenditure on other components within their manufacturing lines.

BEP’s unique proposition allows us to replace an outer steel shell with a fine grain electroformed copper shell, up to 20mm thickness depending on application. The shell is then shrink-fitted over stainless steel guiding spirals welded to an inner core. This provides great strength and enhanced resistance to deformation.

Why copper?

We use copper because its thermal coefficient of heat transfer is 10 times that of steel. This means that during the time the copper shell is in contact with PE, it can absorb up to 10 times more heat. This dramatically reduces the contact time needed compared with steel rolls, allowing the line to operate at greater speeds.

Engineering experts have confirmed that for every 1°C increase in cooling water temperature a 5% saving in energy costs can be delivered. Therefore a copper chill roll operating at 20°C can deliver the same performance as a steel roll operating at 10°C, whilst still offering you the potential to reduce your refrigeration costs by up to 50%.  

Operating chill rolls at 20°C also means that in high humidity climates, condensation does not build up on the cold ends of the roll, reducing product waste.