Wear protection
Built to last,
designed to perform
Powder metallurgy-
-precision components for extreme conditions
Since the introduction of gutbed roll mills in the 1980s, Köppern has been setting standards in the field of wear protection. Through continuous development of innovative high-pressure roll presses and machine components, as well as powder metallurgy-produced roll surfaces, Köppern has established itself as a leading supplier. The two-part design of our wear protection systems comprises a bandage shrunk onto a roll core with an extremely wear-resistant surface. This modular concept stands for maximum service life and cost-effectiveness.
Why Köppern?
Reusability of roller cores
Reusing the roller cores significantly reduces material costs and resource consumption—a clear advantage in terms of cost-effectiveness and sustainability.
Minimization of downtime
The quick replacement of bandages reduces maintenance costs and downtime, which significantly increases plant availability.
Increased productivity and efficiency
Longer service life and optimized rolling performance of the rollers increase the overall performance of the plant and ensure long-term competitive advantages.
Engineered wear protection
for maximum efficiency
HEXADUR®
Specially developed for gutter roller mills in the cement industry. The surface consists of hexagonal wear protection elements of varying thicknesses and offers exceptional wear resistance even under the toughest conditions.
RESIDUR®
Ideal for briquetting and compacting applications. The composite ring has a surface produced by hot isostatic pressing (HIP) powder metallurgy, which guarantees maximum load capacity and a long service life.
HEXADUR®
Reliability-
s in every hexagon
Our HEXADUR® liners for ball mills feature an extremely wear-resistant surface consisting of hexagonal wear-resistant elements (tiles) of varying thicknesses. The hard-phase-containing tiles are manufactured using powder metallurgy and then diffusion-bonded to a high-strength steel ring via a hot isostatic pressing (HIP) process, thereby achieving maximum resistance to damage.
During operation, the spaces between the tiles fill with compressed feed material. This creates a honeycomb-like, self-protecting layer that specifically increases friction between the drum surface and the feed material, thereby improving the feed behavior and material throughput of roller mills with a material bed.
's Multi-Component Wear Protection System
HEXADUR® is a multi-component wear protection system consisting of three different elements.
Captions/Legends:
1. Base body
2. Wear-resistant tiles
3. Tough spacer material
: A Customer- and Application-Specific System Solution
HEXADUR® can be precisely tailored to the customer’s specific application. Thanks to state-of-the-art powder metallurgy manufacturing, it is possible to create material configurations and combinations that would not be feasible using traditional welding or casting processes.
Numerous applications around the world have demonstrated that the service life of HEXADUR® rolls far exceeds that of other wear protection systems. This means longer operating times, less downtime, and lower maintenance costs
Cement grinding
Slag grinding
Blended cement
Record-High Service Life
HEXADUR® achieves exceptionally long service lives worldwide and in a wide variety of applications. One example from the cement grinding industry achieves more than
s Manufactured Using Powder Metallurgy
HEXADUR® delivers exceptional performance worldwide and in a wide variety of applications
HEXADUR® is manufactured using a state-of-the-art powder metallurgy (PM) process. This process involves the targeted combination of different materials to achieve precisely the properties required for each specific application.
In the manufacturing process, a forged steel core (1) is coated with a thick, wear-resistant layer of hexagonal tiles (2) produced via powder metallurgy. The gaps are filled with a special metal powder (3). Hot isostatic pressing (HIP) creates a high-strength, pore-free bond—for maximum service life.
Maintenance and
trouble-free operation
HEXADUR® stands out for its high structural integrity.
The core material (1) offers exceptionally high resistance to crack propagation, ensuring that damage to individual hexagonal tiles (2) does not spread to adjacent tiles (3) and preventing large-scale spalling of the surface.
's self-healing
surface in case of damage
HEXADUR® has a self-regenerating surface effect that ensures high resistance to external influences (foreign materials).
HEXADUR® surface after 1,060 operating hours:
(newly developed localized damage)
Autogenous
Wear Protection
Captions/Legends:
1. Filler material
2. Hexagonal tile
3. Forming depression
: Excellent
Feed performance
Captions/Legend
- Hexagonal tile
- Low-profile hexagonal tile Hexagonal tiles
Significant increases in throughput
The use of HEXADUR® results in higher plant performance thanks to
- maintenance-free operation
- exceptionally low wear
- improved process stability
High profitability and cost-effectiveness
Thanks to its maintenance-free and trouble-free operation, HEXADUR® significantly reduces operating costs and thus ensures high profitability. For existing customers, the typical return on investment (ROI) was achieved within 12 to 24 months of operation.
Since the warranty period and service life of HEXADUR® far exceed the ROI, users benefit from the savings in the long term—without incurring high costs for energy consumption and maintenance.
Typical payback calculations for HEXADUR® compared to other wear protection systems
Contact us
Contact us for your
customized solution
Would you like to learn more about our wear protection systems? Our experts will be happy to advise you and work with you to develop a solution that is precisely tailored to your production requirements.
