How should wax sheets be dipped to ensure proper feeding through the mill rollers? Master the Technique for Smooth Milling

To ensure wax sheets feed properly through mill rollers, the dipping process must maintain consistent grain alignment (90° to the sides), even wax flow, and optimal temperature control. Key steps include holding the dipping board horizontally, pre-heating rollers to 95–100°F, and maintaining a warm milling environment (80–90°F). Incorrect grain alignment (diagonal ripples) or uneven wax distribution can cause feeding issues, while proper handling ensures uniform thickness and smooth milling.

Key Points Explained:

1. Grain Alignment (90° to the Sides)

   • The wax sheet's ripples or "grain" must run perpendicular (90°) to the sides for smooth feeding.
   • Diagonal grain indicates improper dipping, leading to misalignment in the rollers and uneven feeding.
   • Proper grain mimics wood grain, ensuring structural consistency for milling.

2. Horizontal Dipping Technique

   • The dipping board must be held straight (horizontal) during and after each dip into the wax vat.
   • Tilting the board causes uneven wax flow, creating waves or lines that result in non-uniform thickness.
   • Even wax distribution prevents feeding issues like listing (sideways drifting) during milling.

3. Temperature Control

   • Room Temperature: Maintain at least 80°F (preferably 90°F) to prevent premature wax cooling, which hardens sheets and disrupts milling.
   • Roller Pre-Heating: Heat rollers to 95–100°F using boiling water or heating pads. Warm rollers prevent wax from sticking or cracking during compression.

4. Post-Dipping Treatment

   • After UV decontamination and briny water soaking, wax sheets must be handled in a controlled environment to preserve malleability.
   • Rapid cooling (e.g., in cold rooms) can make sheets brittle, increasing the risk of breakage in rollers.

5. Troubleshooting Feeding Issues

   • Diagonal Ripples: Re-dip sheets with proper horizontal alignment.
   • Uneven Thickness: Check for wax flow irregularities during dipping and adjust board angle.
   • Roller Jamming: Verify roller temperature and room warmth; cold wax is less pliable.

By combining precise dipping, temperature management, and grain alignment, wax sheets will feed smoothly through mill rollers without defects.

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