Mill Roll

Cement & Minerals • Niigata, JP

STAR (+4 pts)

APPROVED

Basic Information

Overview

This raw material mill is one of the largest vertical mills in Japan, and in order to continue operations, the customer had been replacing the worn rollers with new ones once a year.

Industry

Cement & Minerals

Location

Niigata, JP

Component/Workpiece

Mill Roll

Business Type

Integra - Workshop

Job Type

Repair

OEM

Ube Industries (Loesche)

Type of Wear

Abrasion

Impact

Problem Description

The challenge the customer was facing

Due to a significant increase in the price of new rollers and delays in delivery, they were facing the issue of being forced to suspend operations for an extended period.

Previous Service Life

Welding Alloys Solution

How WA solved the challenge

This involved collecting the worn rollers that were scheduled for disposal, removing the deteriorated hardfacing layer in the repair areas by gouging, and restoring them to a shape equivalent to new.

Product Category

Integra Services

Product Description

Hardfacing overlay using Hardface HC-O and Hardface CN-O

Job Duration

2mo

Technical Advantages

By reusing rollers that were originally scheduled for disposal, significant cost reductions can be expected. In addition, by adopting welding consumables with superior wear resistance, wear can be minimized, enabling longer equipment life and improved productivity through reduced downtime.

Service Life

1y 6mo

Images (3)

Photos and visuals for this case study

Cost Reduction Analysis

Annual Cost Before

¥16,000,000.00

Annual Cost After

¥5,655,555.56

Annual Savings

¥10,344,444.44

64.0% reduction

Annual Cost Comparison

Previous Solution¥16,000,000.00

WA Solution¥5,655,555.56

Cost Breakdown

Part Information

Cost of Part (A):¥16,000,000.00

Cost of WA Solution (B):¥10,180,000.00

Parts Used/Year (E):1

Solution Lifetime Comparison

Previous Solution:10.1 months

WA Solution:1.5 years

WA solution lasts 1.8x longer!

Before (Previous Solution)

Maintenance/Repair (F):-

Disassembly Cost (G):-

Downtime/Event (H):-

After (WA Solution)

Maintenance/Repair (F):-

Disassembly Cost (G):-

Downtime/Event (H):-

Formula Used

Annual Cost = (A × E) + (E − 1) × (F + G + H)

Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime

Welding Procedure Specification (WPS)

1 layer(s) documented

Submission Details

Contributor

Yuuki Shimizu

yuuki.shimizu@waj.co.jp

Created

April 27, 2026

Submitted

April 27, 2026

Approved By

Laslo Ekres

April 27, 2026

Inspired by this case study?

Join our community and share your own success stories with Welding Alloys solutions