**Abstract**
It wasn’t until the reporter stepped into the acid rolling operation area of the cold rolling company’s rolling mill that their perception of the so-called “in-between†role of the grinding rolls completely changed. Being close to the workers and observing their daily tasks made the reporter deeply appreciate the critical importance of their work, proving that even small places can produce big stories.
The grinding rolls are both “small†and “big.†In the cold rolling company, the grinding team is a modest group, but their responsibilities span multiple production lines, including acid rolling, continuous annealing, and galvanizing. Each roll used in these processes weighs several tons, while the grinding rolls themselves weigh over 40 tons and have a diameter of 1,650 mm. Inside the grinding room, four machines operate in sequence, with workers preparing rolls for grinding. An EDT machine sits between the grinders, and two overhead cranes are in use, operated by two employees loading rolls onto the machines. The environment is dynamic and highly efficient.
Zhang Yueguang, the team leader of the grinding rolls in the acid rolling area, emphasized that understanding how each roll is used across different lines and ensuring stable equipment operation is fundamental. As the demand for acid rolling increased, the number of grinding operations also rose—sometimes more than 30 times a day. This includes grinding the rolls and assembling their bearings. To maintain efficiency, they frequently run production lines to monitor conditions and track roll usage. By adjusting parameters and optimizing programs, they improved grinding efficiency while maintaining quality. Previously, it took about 60 minutes per roll, often requiring re-polishing. After careful analysis and testing, they adjusted the grinding ratios, reducing time by 20 minutes, increasing efficiency by 30%, and achieving one-time success. The recovery rate dropped by 60%, significantly cutting down on roll, wheel, and energy consumption.
In their ongoing efforts to reduce costs and improve efficiency, the team continuously explores ways to optimize processes. For the grinding rolls, the main consumables are the rolls themselves and the grinding wheels. The goal is to minimize consumption without compromising quality or efficiency. They optimized the process to reduce secondary grinding, which helped cut down on both roll and wheel usage. Normally, the grinding amount is 0.2–0.25 mm, but after detailed calculations, they found that some rolls could be ground at 0.15 mm, with all test results within acceptable limits. This led to a monthly savings of 3 mm in roll consumption.
Grinding support rolls are the most expensive part, as each millimeter of grinding uses 40 mm of grinding wheel. With process improvements, the same new wheel can now grind 10 mm instead of 8.5 mm, saving 10 wheels annually. Additionally, electricity, lubricants, and emulsions are also consumed during grinding. To further save on oil, they upgraded the hydraulic station and replaced filter elements, saving two barrels of oil per month—worth nearly 20,000 yuan.
Electricity is another major cost. Through observation, workers implemented a strategy: stopping the grinding wheel rotation when not in use for an hour and turning off the hydraulic system if no rolling occurs for two hours. This saves energy without damaging the equipment.
There is no such thing as the lowest cost—only lower. Though the price of a wheel or a barrel of oil may seem small, the savings from the grinding process add up. It’s in the small details that true dedication and innovation shine through. Starting from the smallest place, they achieved great awareness of cost reduction and created a meaningful story.
Tianjin Alcoa International Trade Co., Ltd. , https://www.tjalcoa.com