Interview with Mr. Kanhaiya Lal, Managing Director, K.L. Engineering Works
Established in 1995, K.L. Engineering Works is a leading manufacturer specializing in corrugated rolls, coating solutions, and precision-engineered gears.
Corrugman : Could we know more about K.L.Engineering Works?
Kanhaiya Lal : We K.L. Engineering, as pioneers in manufacturing and repairing corrugated rollers, we take pride in our expertise and dedication to excellence. Our journey began a quarter-century ago, driven by a passion for innovation and a commitment to quality. Since then, we have consistently delivered superior products and services, earning the trust of clients worldwide.
At KL Engineering works, we understand the critical role that rollers play in the corrugating process. That’s why we combine cutting-edge technology with time-tested craftsmanship to produce rollers of unmatched precision and durability. Whether you need new rollers or repairs, you can rely on us to deliver results that exceed your expectations.
CM : What is your company’s vision?
KL : To be the global leader in the corrugated roller manufacturing sector, renowned for our commitment to cutting-edge technology, sustainability, and unparalleled customer service. We aspire to foster a future where our products drive the highest efficiencies in packaging solutions worldwide.
CM : What products does K.L. Engineering Works offer to the corrugation industry?
- KL : Tungsten Carbide Corrugated Rolls, Hard Chrome Corrugated Rolls,
- Pressure Rolls, Gum Roller & Doctor Rolls and Industrial Gear & Spare Parts are our main products.
CM : Why use hard, wear-resistant coatings on corrugation rollers?
KL : Hard, wear-resistant coatings such as tungsten carbide are essential because they significantly enhance the roller’s resistance to abrasion and corrosion. In the demanding environment of corrugation, rollers face constant friction and mechanical stress. These coatings protect the roller surface, reduce wear, and maintain the precise flute profile for longer periods. This results in improved durability, less downtime for replacements, and consistent quality of the corrugated boards produced.
CM : How do you ensure uniform coating thickness and adhesion?
KL : Uniform coating thickness and strong adhesion are achieved through carefully controlled plating processes and advanced application techniques. At K.L. Engineering Works, precision in the preparation of the roller surface, maintaining controlled environmental conditions, and using specialized plating equipment ensures the coating is applied evenly. Quality control inspections, including thickness measurements and adhesion testing, verify that the coating meets stringent performance criteria, preventing peeling or uneven wear during operation.
CM : How do advanced coated rollers last longer than traditional ones?
KL : Advanced coatings like tungsten carbide provide superior hardness and toughness compared to traditional coatings. This superior hardness prevents surface degradation, cracking, or chipping even under high loads and continuous friction. Additionally, these coatings offer excellent corrosion resistance, which helps rollers withstand moisture and chemicals used in the corrugation process.
As a result, rollers maintain their functional integrity for a significantly longer time, reducing maintenance costs and production interruptions.
CM : Why choose special forged materials for rollers needing hard plating?
KL : Forged materials are chosen because the forging process refines the grain structure of the metal, resulting in enhanced mechanical properties such as strength, toughness, and fatigue resistance. These traits create a robust foundation for hard plating, ensuring the coating remains firmly bonded under stress and mechanical impact. Using forged materials also reduces the risk of internal defects, contributing to longer-lasting rollers capable of withstanding the harsh conditions of corrugated board manufacturing.
With KL Engineering works, you’re not just getting top-quality products and services – you’re gaining a partner committed to your success.
CM : How do you optimize roller surface profiles for better corrugation?
KL : Optimization of roller surface profiles involves precise grinding and fluting to achieve the required flute shape, pitch, and depth essential for quality corrugated board production. K.L. Engineering Works uses advanced CNC grinding and fluting machinery to ensure accuracy and repeatability. The roller’s surface must be smooth yet correctly profiled to form strong corrugations without damaging the paper. Proper profile optimization improves board strength, appearance, and reduces wastage during production.
CM : What maintenance practices help prolong adhesive roller life?
KL : Regular maintenance includes cleaning rollers to remove adhesive buildup, inspecting for wear or damage, and performing reconditioning processes like grinding and re-chroming to restore surface quality. Scheduled inspections prevent small issues from becoming costly failures. Proper lubrication and storage also protect rollers when not in use. These practices ensure rollers maintain optimal performance and have an extended service life.
CM : How do you design rollers to ensure even adhesive application?
KL : To ensure even adhesive application, rollers are precisely machined to have smooth, uniform surfaces and consistent dimensions. Surface treatments can be applied to improve wettability and control adhesive flow. The roller design includes considerations for diameter, surface texture, and rotational speed to distribute adhesive evenly across the board’s surface. This precision prevents adhesive wastage and ensures strong bonding and product quality.
CM : Why use stainless steel for rollers that apply adhesives?
KL : Stainless steel is chosen because of its excellent corrosion resistance, especially in environments where adhesives and moisture are present. It does not rust or degrade easily, ensuring the roller surface remains smooth and uncontaminated, which is critical for uniform adhesive application.
Additionally, stainless steel’s durability helps maintain roller integrity over time, reducing maintenance needs and ensuring consistent bonding quality in corrugated board production.
CM : What design features enhance the efficiency of pressure rollers?
KL : Design features such as self-cleaning surfaces prevent the buildup of adhesive and paper dust, reducing downtime and maintenance frequency. Optimized surface finishes reduce friction and heat generation, improving energy efficiency.
Ergonomic mounting and balancing features reduce mechanical wear and vibration. Together, these elements contribute to smoother operation, less wear on machine components, and higher production speeds.
CM : What about your expansion plans?
KL : KL Engineering Works is proud to announce the inauguration of our new manufacturing facility located in Gautam Budh Nagar, Uttar Pradesh. This state-of-the-art unit has been strategically established to cater more efficiently to the Central Indian market, ensuring faster deliveries, improved service, and greater accessibility for our clients across 18 states.
With this expansion, our production capacity is projected to reach 250 sets per annum by 2026, reinforcing our position as one of India’s leading manufacturers of corrugated rollers. This milestone reflects our commitment to innovation, quality, and customer satisfaction.
In addition to infrastructure growth, we continue to invest in skilled manpower, advanced machinery, and environmentally responsible practices. Our dedicated team of engineers, technicians, and support staff work tirelessly to uphold the highest standards of precision and reliability.