The rollforming machine

One of the most common building and construction materials is the steel stud and track.  The machine that is used to form these steel studs and track is the "Stud and Track Roll Forming Machine".  The common configuration includes advanced features such as automatic material thickness (gauge) control and material handling systems.  Production rates as much as 500 fpm the fabrication of studs and tracks must roll out without failure.  The rollfromer is an integral part of the success of any stud supplier and is often the heart of the operation.

Drywall Machine

Industrial building and construction projects rely on drywall steel stud systems.  The quick installation and light weight characteristics of steel framing makes this an ideal product.  Many job site forming machines lack the ability to produce stud and track to the right tolerances.  The installation of drywall requires the use of the correct drywall tools.  These tools are engineered to match standard stud sizes used in commercial building.   The drywall machine, or rollformer, must continuously produce the same sizes regardless of the steel coil used.

Stud Rollformer Equipment

The most common installation for stud rollforming includes a number of auxiliary equipment.  This equipment aids in the forming of the sheet metal into the correct studs and channels.  The equipment required in rollform studs includes; 

• Uncoiler
• Flatenner
• Sheet Metal Lubricator
• Pre-cut Dies
• Pre-notching Press
• Rolling Mill
• Roll Tolling Stands
• Post Cut Press
• Flying Cut-off

Option Accessories

Many installations operate at very high speeds.  For stud and track roll forming it’s common to reach line speeds of 500fpm or more.  For the overall operation to be successful manufacturers must keep in mind the post production requirements.  As the forming machine discharges the stud at a high speed material handling equipment is required to stack and package the steel sticks in to bundles.  Automated conveyor systems such as the following are typically required.

• Stacker
• Bundler
• Wrapper

Rollforming Machine Features

Integrating the rollforming machine in to your material handling software is critical to minimizing material waste.  These two systems can ‘speak’ to each other in such a way that loading of specific coils and steel material types are selected.  Having automated features within the roll former such as, auto web width, auto material thickness and auto flange height greatly increase the build to order process.  With pulse generators and photo eye alignment sensors throughout the rolling mill PLC programs constantly monitor the high speed operation of the line.

Samco Machinery Video – Automotive Rollforming

In this video rollforming machine manufacturer "Samco Machinery" demonstrates how they have designed and engineered a complete system for forming car bumpers.  The Tata Nano, "The Peoples Car' utilizes several forming machines in order to manufacture the under carriage chassis and bumper.  Integration of the bending and forming steps has given Tata an advantage over other automotive Tier 1 parts suppliers.

Other roll forming machine manufactures such as Roll-Kraft have developed their own innovative solutions for this sector.  The Auto Pro 315 leverages their steel forming technologies to enable them to meet this demanding market.

For more information on automotive rollforming machines contacts us today!

http://www.youtube.com/watch?v=u-UzybaiYss

There are two types of rollforming machines used to manufacture stud and track.  The more common machine is the stud and track rollformer that is used to manufacture drywall studs.  These machines produce studs and very high rates allowing you to produce at a lower per part cost.

The second type of rollforming machine is the structural steel rollformer.  This machine is engineered to handle the larger material and is built “heavy duty”.  The overall functionality is the same as the drywall stud machine however speeds are reduced as a result of the material thickness.

The world leaders that manufacture industrial grade steel stud and track rollforming lines all have installations with the largest suppliers and producers of steel studs.

Learn more about the Stud & Track Rollformers and how they work

Read more about the various features and functions on the stud maker machine in our rollformer blog.

Drywall Stud Machine Lines

Watch the stud and track rollformer in action in this product video

• Drywall Stud Rollforming Video

Stud Rollforming Machine

The cost of steel stud framing is a critical consideration when designing a steel home.  In order to be cost effective manufacturers of light steel framing products utilize high-speed rollformers.  These machines are engineered for high volume production which directly impacts the per part cost.  The second critical factor affecting the metal stud and drywall calculation is the material specifications.   The rollforming machine line speed can reach as high as 550FPM while running non-load bearing 20-25 gauge (GA) galvanized steel coil.  At these speeds the rollformer can maintain specification tolerances on length accuracy of +/- 0.032”

Steel Structural Lines

The manufacturing of structural steel products requires a specialized stud and track rollforming machine.  The material standards, requirements and shape dimensions are all critical when producing load-bearing products.  Typical material thicknesses for floor joists and stud or tracks is 12, 14 and 16 gauge (GA) with a minimum 55 yield stock.  Structural lines include rapid change over designs with integral pre-cut and post-cut dies.  This allows for continuous operation and the ability to change over the flange height and web width virtually with the touch of a single button.

Full integration with high speed automated packaging systems including bundlers, stackers and strapping systems reduce labor costs and per unit costs.  The heavy duty design and construction allows for 24/7 operation under any circumstance.

Custom Roll Tooling Design Services

Many drywall studs require specialized “proprietary” patterns on the web or flange in order to deliver the required structural requirements.  Also, suppliers may want to ‘brand’ their products with embossing their name or product number in to the steel.  All of this requires specialized tooling within the rollformer.   Many of the leading manufactures for steel studs partner with a rollforming machine company that is capable of assisting them in the development and design of their unique roll tooling stud requirements.

Stud and Track Rollforming  Video

• Drywall Stud and Track Machine Video

Rollformers

• Bradbury Stud Mills
• Sen Fung Model SF-240L
• Gasparini C/U Machine
• Samco Greenfield
• Samco Studmaker™
• Samco Workhorse

System Specifications and Capabilities

• Fully Automated Profile Selection
• High Speed Production Rates
• Quick Change Over Tool Design
• Turnkey Software Integration
• Master Bundler and Stacker Packaging Systems
• Automated Material Handling Conveyor Systems

Our History

With over two decades of experience in the industrial machinery business we have built a reputation as knowing your business.  Our industrial equipment experience spans many industries and includes a range of product specialties such as rollforming, uncoilers, punch presses and conveyor metal detection equipment.

Industry Stewardship and Position in the Market

Building equipment is only part of the commitment we bring to the industry.  Our approach is to deliver both what our customer needs and engage with the industry as a whole to improve the future.

• Industry Leadership
• Innovative Designs
• Development and Research 

Rollforming Customers 

Companies that use rollforming systems in the manufacture of their drywall stud and tracks

• Clark Dietrich
• Bailey
• Imperial Group
• Studs Unlimited
• California Expanded Metal Products Co.
• Custom Stud, Inc.
• MarinoWare

The Samco Greenfield Studmaker is an industrial leader in the manufacturing of steel framing channels.

The Samco Studmaker has been designed to manufacture studs from 3 5/8" to 14" in width with flange heights ranging from 1 3/8" to 2 1/2".  Material thickness can range from 20 (.039) to 12 (.112) with 3" rollformed deep leg tracks.  All of this can be manufacturered without shear's or dies.

Samco Roll Forming

The "Samco Roll Forming" machine Studmaker is designed for quick change-overs, typically under 20 minutes, which in turn allows you to manufacture 24/7.  This high speed capability and size change speed is another innovative design first introduced by Samco Machinery ltd.

Piercing and Cutt-Off

Optional pre-pierce and pre-shear hydrex dies can be provided on the Studmaker.  If you have an older model you can benefit from the upgrade of these accessories.

Rollformer

Industries such as the building and construction sector are heavy users of steel products.  Everything from steel framing, standing seam roofing, sandwich panels and purlins are made by a roll forming machine.  The history of cold forming dates back to the 20's.  Scandinavian  companies were one of the first to incorporate this technology to produce tile effect roofing.

Forming machine and roll tooling

An area that has often been seen as 'black magic' is the design of roll tooling.  In years gone by craftsman used their experience and knowledge to design each roll stand for optimum performance.  As you can imagine this was a slow and unpredictable process for metal forming.  Now roll forming machine manufacturers utilize a software application called COPRA FEA.  This software program simulates each roll pass so that designers can fast track machine manufacturing.

Common applications of forming equipment

Consumers are most commonly aware of roll forming machines used to manufacture on site gutters or steel studs.  These portable rollformers are not that much different than there big brother.  They share the same machine requirements such as drive, controller or PLC, roll tooling and cut-off.  Most industrial metal rolling applications include a number of accessory equipment. 

For more information on roll forming machines contact us today.

The process of forming steel has been around for decades.  In its basic state the forming machine pulls in sheet metal and passes it through a set of steel rolls called roll tooling.  The roll tooling bends and forms the flat sheet metal in to a shape or profile.  

Cold Roll Forming

The term ‘cold forming’ comes from the fact that the roll of steel is not heated and is at ambient temperature.  Both the metal roll material and the forming machine tooling are ‘cold’.  There are processes that heat the roll of metal prior to forming it, this is called ‘hot forming’.

Roll Forming Machinery

Forming machinery is capable of producing a wide range of end profiles or products.  As the rollforming industry continues to grow worldwide so do the demands for ever complicated profiles.  From simple U Channels used in metal framing to complex sandwich panel shapes machine forming can solve many design requirements.

An industry that has adopted across many applications the use of formed steel products is the building and construction industry.  For practical reasons such as speed of installation and simply use steel framing products such as the stud and track have been widely utilized.  Some of the more common products found in commercial projects are:

• Corner Bead
• Eavestroughing
• Siding
• Roofing Panels
• Structural Steel
• Floor Decking
• And more…

The advantages of rollforming metal are plenty and often much more cost effective than other metal forming processes.  Today’s roll former manufactures are often pushed by the creativity and demands of the marketplace.  Today it seems that there are few limits to this technology.

A recent project designed and built by KBW Associates in Memphis Tenn., saw some pretty cool advancements in building technology.  New features allowed for an off-center ridge with a continuous beam frame system to increase substantially the usable space.

Steel Framing System

This two story building has over 44,000 square feet of research and office space.  Utilizing many steel building components, such as siding, steel stick framing and roll formed Z/C purlins this building reduces dramatically its carbon footprint.

You can read more about it at Metal Mag here.

CEE and ZEE Purlin Rollformer Machines

There are many common sizes for standard C and Z Purlins.  The hole patterns and notches cutout are also very common.  For more information on Purlin Roll Formers check out our product page.

The manufacturing of steel stud and track used in today's industrial construction relies heavily of through-put.   A highly commodity based industry the manufacturing of steel framing is all about cost.  The cheaper you can pump out the sticks the better off you are, plain and simple.  Some manufacturers design their light gauge framing components with special ribbing or knurling to separate themselves in the marketplace.  Now, this could very well be a highly valuable feature when constructing interior steel walls.  However, at the end of the day most builders will decide largely based on cost.

How to manufacture steel framing studs with a roll former.

This is where the stud and track roll former such as the Samco Greenfield come in.  These machines can manufacture virtually all of the sizes required for conventional steel stick framing.  They can also integrate special features such as knurling or 'stampings' in to the web of the stud.  With the ability to produce high volumes, special features and custom sizes industrial level rollforming allows produces of steel framing to increase margins while being competitive.

There are many roll forming machine manufactures around the world.  The question as to what company is the right one to produce roll formed profiles can be tough to answer.   So where do you start?  Looking at a roll forming machine for building corrugated roofing sheets must take in to consideration several key factors.  The machine durability is one of the most over looked elements in the decision making process.  Too often companies choose largely based on price rather then quality.  This often leads to roof panels that are manufactured poorly and require re-work or scrapping.  This will lead to a higher cost per panel when roll formed with a low cost machine.  The roll forming process is very precise even for the most common roll formed profiles and shapes.  The use of sheet metal to make roofing panels has long been the material of choice.  The sheet metal forming process to produce the corrugated profiles utilizes many machines in order to manufacture quality panels.  The tools and dies on these machines are an important part of the overall quality.  Also the strength of each roll tool stand is equally important in producing quality profiles over and over.  Can you imagine using small lightweight roll tooling or stands to bend sheet metal reliably?  It is obvious that you must use a strong machine built by a reputable company who has years of experience.  One such company Samco Machinery, is well known around the world for producing quality machinery for the roofing panel industry.  They also have a roll forming machine division in India to produce local equipment.  If you’re looking for a roll forming line to manufacture corrugated roofing or wall panels I would start with a leader in the market.  Companies like Samco (http://www.industrial-machinery-news.com/roll-forming/smi) manufacture custom machinery that are highly cost effective.  

Interior Construction of Office Buildings 

The most common wall manufacturing technique used in today’s modern office tower is that of steel stud and track.  Speed, cost and weight are the driving forces for this preferred building method.  Having the ability to cut quickly and join simply any interior wall design makes the C channel and U channel steel framing product the only choice.

How do they make steel stud and track?

Stud and Track Wall Roll Former

Large heavy duty stud and track roll formers manufacture with a high degree of accuracy all of the common profiles.  Some manufacturers even offer stud and track wall machines that automatically switch between profile sizes.  This allows manufactures of steel framing products the ability to produce ‘made to order’ bundles of products.  Having this capability along with the capacity to produce thousands of pieces makes the building material highly cost effective.

Onsite Stud and Track Wall Fabrication

Some builders prefer to manufacture the steel framing studs on site.  The rollformer is a lower grade the its industrial cousin however it allows for even higher flexibility.  On some projects the roll forming machine is raised to the floors where it’s needed.  This allows the construction crew to manufacture on demand the materials they need.