helen@hbxinnuorollforming.com
Dual-profile IBR and color coated sheet roll forming with hydraulic cutting
Compact two-in-one machine body saves 45% factory floor space
PLC touchscreen auto-control adjustable production length and batch quantity
Hard chrome-plated 45# forged steel rollers prevent surface paint damage
Heavy-duty chain transmission ensures smooth continuous high-speed operation
Quick 10-15 minute profile switching with manual material path adjustment
Factory-direct supply with on-site installation guide and remote support
This advanced double layer roll forming machine is engineered to produce two distinct steel roofing profiles from a single compact machine body — eliminating the need to purchase and house two separate production lines. The upper forming station shapes standard IBR (Inverted Box Rib) trapezoidal roof sheets, while the lower station produces color coated corrugated roofing panels. By simply redirecting the coil material feed path, operators switch between profiles in approximately 10 to 15 minutes, making it an ideal solution for roofing manufacturers who serve diverse market demands without doubling their equipment investment.
The machine carries two independent sets of precision roller stations mounted vertically on a shared heavy-duty structural frame and driven by a unified chain transmission system. When producing IBR sheets, the galvanized or color coated steel coil enters the upper roller assembly where 14 to 18 forming stations progressively bend the flat strip into the required trapezoidal rib geometry. When switching to corrugated color coated sheets, the operator adjusts the entry guide plate and redirects the coil into the lower roller set, which features a different roller profile configuration optimized for corrugated or sinusoidal wave patterns. Both layers share the same main drive motor, hydraulic cutting station, and PLC control panel, achieving significant cost savings on components while maintaining independent profile precision.
| Component | Specification and Function |
|---|---|
| Main Frame Structure | Welded heavy-gauge steel H-beam or channel steel frame (300H–400H grade), heat-treated for stress relief, supporting dual roller assemblies with zero deformation under continuous load |
| Forming Roller Stations | 14–20 rows per layer, CNC-machined from 45# forged steel, surface-hardened and mirror-finished with hard chrome plating (HRC 58–62), preventing paint scratching and rust on color coated coils |
| Solid Drive Shafts | Φ75–Φ85mm precision-ground alloy steel shafts, keyway-locked to each roller set, delivering uniform torque distribution across all forming stations |
| Chain Transmission | Heavy-duty double-row roller chain (6分双排 or 1寸双排), enclosed in protective steel guard covers, synchronized between upper and lower drive systems |
| Main Drive Motor | 5.5 kW – 7.5 kW industrial AC motor with gear reducer, providing stable variable-speed output controlled via PLC inverter |
| Hydraulic Cutting System | Post-cut design with Cr12MoV heat-treated alloy steel blade, 4.0 kW hydraulic power unit, executing fly-shearing cuts without interrupting continuous forming flow |
| PLC Control Panel | Touchscreen HMI with multi-language support (Siemens / Delta / Mitsubishi options), programmable sheet length, batch counter, automatic fault diagnostics, and emergency stop function |
| Material Entry Guide | Manual adjustable guide rails with side-roller alignment, integrated manual pre-shear blade for trimming coil ends before entering forming zone |
| Run-out Table | 3-meter to 5-meter receiving table with support rollers, ensuring cut sheets stack neatly without bending or surface contact damage |
| Parameter | Standard Range |
|---|---|
| Effective Sheet Width | 762 mm / 840 mm / 925 mm / 1050 mm (custom profile available) |
| Rib Height | 28 mm – 43 mm |
| Peak Count | 5 ribs (standard); 4 or 6 ribs optional |
| Feed Coil Width | 1000 mm – 1250 mm |
| Parameter | Standard Range |
|---|---|
| Effective Sheet Width | 750 mm / 900 mm / 1000 mm (depending on corrugation pitch) |
| Wave Height | 12 mm – 25 mm |
| Wave Count | 5 – 10 waves |
| Feed Coil Width | 1000 mm – 1220 mm |
| Specification Item | Standard Configuration |
|---|---|
| Applicable Raw Material | PPGI (pre-painted galvanized iron), PPGL, hot-dip galvanized steel coil, aluminum-zinc coated coil, aluminum sheet |
| Material Thickness Range | 0.3 mm – 0.8 mm (adjustable via roller gap screws) |
| Forming Speed | 12 – 18 meters per minute (PLC variable speed control) |
| Cutting Tolerance | ±1.5 mm (length); ±0.5 mm (profile geometry) |
| Profile Switching Time | Approximately 10 – 15 minutes (manual guide plate adjustment) |
| Machine Dimensions (L×W×H) | Approx. 7.5 m × 1.5 m × 1.8 m (varies by profile configuration) |
| Machine Weight | Approx. 5.5 – 8.0 metric tons |
| Electrical Requirement | 380V / 50Hz / 3-phase (custom voltage and frequency matched to destination country) |
| Optional Accessories | 5-ton or 8-ton hydraulic decoiler, automatic coil car, stacker system, remote IoT monitoring module, spare roller set, tool kit |
A complete double layer IBR and color coated sheet production line consists of the following sequential stations:
| Comparison Factor | Two Separate Single-Layer Machines | One Double Layer Machine |
|---|---|---|
| Factory Floor Space | Approx. 45–70 m² combined | Approx. 20–35 m² (about 45–55% less) |
| Equipment Purchase Cost | Sum of two full machine prices | Approximately 65–75% of two-machine total |
| Installation Time | 2 separate foundations and setups | Single foundation, single installation cycle |
| Operator Requirement | 2–3 operators per line | 1–2 operators for both profiles |
| Maintenance Complexity | Two independent maintenance schedules | One unified maintenance routine |
| Production Flexibility | Run both profiles simultaneously | One profile at a time, switch in 10–15 min |
| Shipping & Logistics | Two separate container loads or shipments | Single container, lower freight cost |
This machine serves a broad spectrum of steel construction applications:
Every forming roller undergoes CNC lathe turning, precision grinding, and hard chrome electroplating with thickness inspection. The main frame is welded on a positioning jig and then subjected to thermal stress-relief annealing to eliminate residual weld stress. All drive shafts are dynamically balanced before assembly. The fully assembled machine runs a no-load test for a minimum of 4 hours, followed by a full material trial run using customer-specified coil thickness and profile dimensions. Only after passing all inspections — including dimensional tolerance checks on 20 consecutive sample sheets — is the machine approved for packing and export shipment.
The machine is shipped in standard 20-foot or 40-foot HQ containers with multi-layer protective packaging: the main machine body is wrapped in heavy-duty plastic film with industrial desiccant packs, then secured to a reinforced steel pallet or directly into a fumigated plywood case. All exposed metal surfaces receive anti-rust oil coating. Loose components including the control cabinet, hydraulic station, and tool kits are packed in separate marked wooden crates. On-site installation supervision by experienced engineers is available upon request, along with 24/7 remote video support, a detailed English operation manual, and a complete set of electrical schematic diagrams. Spare wearing parts (shear blade, chain links, limit switch, emergency stop button, sealing rings) are included free of charge with every machine delivery.
