Laser Cleaning for Paperboard Rollers
How Manchester Industries Beat Rust & Met Their Deadline
Project Snapshot
When Manchester Industries launched its new facility in Blythewood, SC, several critical paperboard rollers had developed heavy rust after being stored in an open-air structure during the construction of their new facility. Replacing these rollers would be costly and slow; manual cleaning was estimated at 2 people, 80+ hours and would require grinding the surface that could lead to an uneven roller profile.
Merritt Industrial, Charlotte, NC mobilized a 1,000W pulsed laser and one technician.
Outcome: Rollers were cleared of rust scale in 16 hours, in place, with no disassembly—keeping the grand-opening on schedule and saving ~90% of the projected labor (≈144 labor-hours avoided).
In-place cleaning saved thousands in specialized millwright labor and avoided disassembly/realignment risk.
Laser cleaning of the paperboard roller. Quick rust removal.
Why Laser Cleaning Works for Paper & Packaging Equipment
- Non-abrasive to the base metal
The laser targets rust scale, not the substrate material, preserving roller geometry and finish that matter for product quality. - In-place cleaning (CIP-style)
No teardown means fewer specialized parts disturbed, fewer alignment checks, and immediate return to service. - Minimal secondary waste
Laser Rust Removal requires no blast media. What’s collected is mostly loosened oxide dust, making containment cleanup quick and less risk of cross contamination. - Detail & access
Lasers reach fasteners, edges, keyways, drive gears and guards that are difficult or impossible to access with manual tools or media. - Chemistry-free
No solvents or harsh chemicals near bearings, sensors, or electronics.
Does Laser Cleaning Actually Remove Rust?
Yes. Both pulsed and continuous-wave industrial lasers are proven for rust and scale removal. The process combines:
- Selective absorption – Rust absorbs the laser, heating and fracturing the oxide layer.
- Micro-ablation – Short, intense pulses break the bond between scale and substrate.
- Thermal shock & lift – Contamination releases from the surface; a vacuum or wipe-down clears residue.
Because the parameters are tuned to the oxide, the base steel remains intact, helping clients avoid refinishing or replacement costs.
Dry Ice, Abrasive, or Laser—Which Should You Choose?
- Choose laser for rust/scale removal on high-value components where you must protect geometry and finish and want minimal waste.
- Choose dry ice blasting for broad contamination (inks/adhesives/oils) when you need non-abrasive cleaning more than oxide removal.
We evaluate each project and make an experienced based recommendation for the the fastest, lowest-risk path for your equipment and schedule. Often times we find a combination of dry ice blasting and laser cleaning works best for rust remediation, but using both technologies on the same project can influence overall project costs.
Laser cleaning for Paper Equipment video library
FAQ
Will laser cleaning damage rollers?
Not when correctly configured. We tune power, frequency, and scan speed to remove rust while protecting the substrate.
Do you have to remove the rollers?
Usually no. Most paper machine components can be cleaned in place, reducing downtime and rigging costs.
Is there media to dispose of?
No blasting media. Only light oxide dust, which we capture with localized extraction and wipe-down.
How fast is it?
Project-dependent, but our recent job finished in 16 hours with a single operator—work the client expected would take two people several weeks.
How Expensive is Laser Cleaning?
Laser cleaning pricing can be influenced based on the project location, laser type and wattage, contamination scale, required finish and schedule urgency, but typically ranges between $250-$350 per hour for in-shop cleaning and $300-$500 per hour for field work.
About Merritt Industrial
Merritt Industrial (Charlotte, NC) provides laser cleaning and industrial surface preparation across NC, SC, VA, GA, and parts of TN. We specialize in manufacturing equipment cleaning, including paperboard and packaging equipment, helping plants hit commissioning dates, turnaround windows, and quality targets with minimal disruption.
Need a site review or demo?
Call Today! We can typically mobilize within 24–72 hours for emergency services.