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The design of work roll cooling systems and their operation can be systematically optimized by a scientific methodology. This methodology applies: (1) fundamentals of design based on deeper insight into the heat transfer phenomena, (2) a comprehensive rolling operations knowledge, and (3) detailed and accurate mathematical modeling. The objective is to generate a cooling configuration that accomplishes the desired function of the system while meeting the technical and economical constraints of the plant. The successful application of this methodology is presented for a multi-stage upgrade of an existing operation. This method has proven to be successful to obtain optimum cooling configurations that fit all the important technical and economical constraints found in practical rolling operations. Detailed thermal modeling simulations allowed the development of proper design criteria and operational criteria to improve roll cooling performance, and provide meaningful, quantifiable forecasts of performance for any proposed design.