RocCera has the in-house expertise to cost-effectively manufacture the toughest ceramics known today. One of these materials is RTZ (RocCera Tetragonal Zirconia polycrystal). Low cost has not been an attribute readily associated with ceramics which are hard to machine. "Net-shape" manufacturing technology circumvented that problem whereby eliminating or drastically reducing the machining cost. These technologies enabled RTZ ceramics to compete head-on with steel and other structural materials. All these factors contribute to a longer life, higher reliability and greater profitability.
A Product of Kodak Research
A family of patented zirconia ceramics and composites was developed by Dr. Ghosh at Kodak Research Labs to meet Eastman Kodak's demanding film manufacturing processes; processes that do not tolerate downtime; processes that generate high surface wear in a highly corrosive atmosphere.
Kodak has been using structural and optical ceramics for over 25 years. In 1981, SiC ceramic was first used as nubbin material – the only technology in the world - for molding precision glass lenses at high temperatures. SiC ceramics were used to redesign and replace steel bearings in chemical delivery pumps for making acetate webs. This patented technology was used to replace more than 10,000 gear pumps in Kodak.
Dr. Ghosh initiated the structural ceramic research program in 1992 for a broader application of oxide ceramics in high speed manufacturing processes. The original focus of the structural ceramic research program was to achieve cost effectiveness and toughness, with at least 5X longer service life
After his retirement from Kodak, Dr. Ghosh founded RocCera LLC in 2006 to design and manufacture advanced ceramic zirconia components.
Long Lasting and Low Cost
RTZ rollers in film manufacturing transport systems lasted twelve times longer than chrome plated hardened steel rollers at substantially lower cost. Ceramic rollers not only improved the manufacturing productivity, but also greatly improved the product quality (almost zero rejection) as there were no wear or corrosion induced debris to contaminate the film products. Implementation of ceramic rollers in Kodak's manufacturing processes replacing forever the age-old steel parts was one of many successful stories.