**Abstract**
It was only after stepping into the acid rolling operation area of the cold rolling company that the reporter completely changed their previous perception of the so-called "in-between" role of the grinding rolls. Being physically close to the workers and observing their daily tasks gave the reporter a new appreciation for the importance of their work, proving that even small details can lead to big stories.
In fact, the grinding rolls are both "small" and "large." On one hand, the team is relatively small within the company; on the other, they play a critical role in multiple production lines, including acid rolling, continuous annealing, and galvanizing. The rolls themselves vary in size, with some weighing just a few tons, while others—like the massive grinding rolls that weigh over 40 tons and have a diameter of 1,650 mm—require specialized handling. In the grinding room, four machines operate in sequence, with workers actively preparing the rolls before they are processed. An EDT machine sits between the grinding units, while two overhead cranes lift and move the heavy rolls. The entire space is bustling with activity, showing how essential this process is to the overall production flow.
Zhang Yueguang, the squad leader of the grinding team in the acid rolling area, emphasized that understanding the usage of each roll across different production lines and ensuring equipment stability is fundamental. As the demand for acid rolling increased, the number of grinding operations also rose significantly—sometimes exceeding 30 times a day. This includes not only the grinding of the rolls themselves but also the assembly of bearings. To maintain efficiency, the team frequently runs test programs and monitors the condition of the rolls. By adjusting parameters and optimizing processes, they improved grinding efficiency by 30%, reduced rework, and achieved a 60% decrease in recovery rates, significantly cutting down on the consumption of rolls, grinding wheels, and energy.
In their efforts to reduce costs and improve efficiency, the team constantly explores ways to optimize operations. For the grinding rolls, the main consumables are the rolls themselves and the grinding wheels. Balancing cost reduction with quality and efficiency is the key goal. They revised the grinding process to minimize secondary grinding, which helped lower the consumption of both rolls and grinding wheels. Normally, the grinding amount is set at 0.2–0.25 mm, but through careful calculations, the team found that certain rolls could be ground at 0.15 mm without compromising quality. This change led to an average monthly savings of 3 mm per roll.
For the grinding wheels, which are among the most expensive consumables, the team optimized the grinding process so that a single wheel can now grind up to 10 mm instead of 8.5 mm. This means saving 10 new wheels annually. Additionally, they reduced oil consumption by upgrading the hydraulic system filters, saving about 2 barrels of oil per month, equivalent to nearly 20,000 yuan. They also saved electricity by implementing smart operational practices, such as stopping the grinding wheel rotation when the machine is idle for an hour and shutting down the hydraulic system when no rolling is happening for two hours. These small but effective changes helped reduce energy use without harming the equipment.
There’s no limit to cost reduction—it’s always about going lower. Although the cost of a grinding wheel or a barrel of oil may seem small, the cumulative savings from these tiny improvements show the team's deep commitment to efficiency. Starting from the smallest details, they have made a significant impact, proving that real value lies in the little things.
Tianjin Alcoa International Trade Co., Ltd. , https://www.tjalcoa.com