helen@hbxinnuorollforming.com
One machine two profiles IBR and corrugated roll forming for sale
Upper and lower roller decks on single welded structural steel frame
Hydraulic flying shear cuts moving sheet at preset length automatically
PLC control panel with digital counter stores multiple job recipes
Chrome hardened rollers eliminate scratches on coated metal strip surface
Quick deck changeover by repositioning entry material guide diverter
Factory tested and shipped in one container with complete documentation
This double layer roll forming machine is offered for sale as a complete turnkey production solution that manufactures two distinct metal roofing profiles from a single compact unit. The upper forming deck produces IBR (Inverted Box Rib) trapezoidal panels — the industry standard for structural roofing across commercial and industrial construction. The lower deck simultaneously houses tooling for traditional corrugated wave sheets — the most widely consumed affordable roofing material in developing markets worldwide. By consolidating both profile capabilities into one machine body, manufacturers eliminate the floor space, capital cost, and maintenance burden of purchasing and operating two separate roll forming lines.
The machine frame is fabricated from heavy-gauge welded structural steel members, forming a rigid box-section chassis that resists torsional flex and vibration during high-speed continuous forming. The frame undergoes post-weld thermal stress relief in an industrial furnace, followed by precision surface machining at every bearing pad location to achieve exact shaft parallelism across all roller stations. The drive train begins with a single AC induction motor coupled to a worm-type speed reducer with dual output shafts. Each output shaft drives a dedicated heavy-duty roller chain loop — one powering the upper IBR deck, the other powering the lower corrugated deck. Independent chain tensioners on each loop allow operators to fine-tune drive slack without affecting the opposite deck.
| Tooling Attribute | IBR Forming Deck | Corrugated Forming Deck |
|---|---|---|
| Number of Stations | 14–18 roller pairs | 13–16 roller pairs |
| Roller Material & Grade | 45# medium carbon forged steel | 45# medium carbon forged steel |
| CNC Machining Process | Contour turning to IBR rib profile geometry | Contour turning to sinusoidal wave profile geometry |
| Hardening Method | Case hardening + hard chrome electroplate | Case hardening + hard chrome electroplate |
| Chrome Layer Thickness | 0.05–0.08mm minimum | 0.05–0.08mm minimum |
| Roller Surface Hardness | HRC 58–62 | HRC 58–62 |
| Roller Shaft Diameter | Φ75–Φ80mm 40Cr alloy steel | Φ75–Φ80mm 40Cr alloy steel |
| Bearing Support Type | Double-row self-aligning pillow block bearing | Double-row self-aligning pillow block bearing |
| Gap Adjustment Mechanism | Individual screw-down at each station, 0.05mm precision | Individual screw-down at each station, 0.05mm precision |
| Parameter | Available Specifications |
|---|---|
| Effective Coverage Width | 762mm / 840mm / 925mm / 1000mm / 1050mm / 1100mm |
| Rib Configuration | 4-rib, 5-rib (most common), or 6-rib layout |
| Rib Height from Valley | 28mm to 43mm depending on model |
| Rib Base Width | 50mm–65mm internal dimension |
| Side Lap Configuration | Standard single overlap or anti-capillary groove overlap |
| Flat Coil Feed Width | 1000mm–1250mm before roll forming |
| Parameter | Available Specifications |
|---|---|
| Effective Coverage Width | 660mm / 750mm / 800mm / 900mm / 1000mm |
| Wave Count per Panel | 5, 7, 9, or 11 waves |
| Wave Depth (Crest to Trough) | 12mm to 18mm overall |
| Wave Pitch Spacing | 76.2mm (3-inch standard); 60mm–100mm custom |
| End Lap Recommendation | 150mm minimum longitudinal overlap for weather tightness |
| Flat Coil Feed Width | 914mm–1220mm before roll forming |
| Specification Item | Technical Data |
|---|---|
| Compatible Input Materials | Hot-dip galvanized steel coil (GI), pre-painted galvanized iron (PPGI), aluzinc/Galvalume (AZ), cold-rolled steel strip, aluminum sheet 1100/3003 series |
| Material Thickness Range | 0.25mm to 0.80mm (approx. 30-gauge to 20-gauge) |
| Material Yield Strength Range | 200 MPa to 400 MPa (mild steel through structural grades) |
| Forming Line Speed | 10 to 18 meters per minute, stepless variable via VFD inverter |
| Main Drive Motor Rating | 5.5kW or 7.5kW AC induction, 4-pole, 1440 rpm, IP54 enclosure |
| Gearbox Specification | Worm gear reducer, ratio 1:40 or 1:59, oil-bath lubrication, dual output shaft design |
| Chain Drive Type | Heavy-duty double-row industrial roller chain per deck, fully enclosed guard housing |
| Hydraulic Pump Motor | 4.0kW, 4-pole, direct-coupled gear pump, 16–21 MPa working pressure |
| Cutting Shear Type | Flying hydraulic post-cut, carriage-mounted, synchronized with line speed, Cr12MoV alloy steel blade HRC 60–64 |
| Length Accuracy | ±1.0mm via rotary encoder feedback to PLC with auto-compensation algorithm |
| PLC Controller Options | Siemens S7-1200 series, Delta DVP series, or Mitsubishi FX3U series per buyer preference |
| Operator Interface | 7-inch or 10-inch color LCD touchscreen, multi-language, programmable recipe storage |
| Electrical Power Requirement | 380V 50Hz 3-phase standard; custom voltage (220V/415V/440V/480V) and frequency (50Hz/60Hz) available |
| Profile Changeover Method | Manual pivoting diverter plate redirects strip to upper or lower deck; 10–15 minute changeover time |
| Machine Dimensions (L×W×H) | Approximately 7.0–8.0m × 1.4–1.6m × 1.7–2.0m depending on profile configuration |
| Machine Net Weight | 5.0 to 7.5 metric tons depending on roller count and frame specification |
| No. | Equipment Name | Description |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | 5-ton or 8-ton load capacity; hydraulic jaw expansion grips coil ID; manual disc or pneumatic band brake for controlled tension pay-off; loop height sensor modulates decoiler rotation speed to maintain consistent strip buffer |
| 2 | Feed Guide and Pre-shear Unit | Adjustable-width side alignment rollers center the incoming strip; manual guillotine blade trims the coil leading edge square before threading into forming deck entrance |
| 3 | Double Layer Main Roll Forming Machine | Core production unit with upper IBR deck and lower corrugated deck on single frame; pivoting diverter plate selects active material path; shared motor, chain drive, and hydraulic shear |
| 4 | Hydraulic Flying Post-cut Station | Carriage-mounted Cr12MoV alloy shear blade assembly; pneumatic clamp grips sheet; hydraulic cylinder drives blade through profile cross-section; carriage returns to home after each cut |
| 5 | PLC Electrical Control Cabinet | IP54 rated steel enclosure with PLC, VFD inverter, relays, contactors, overload protectors, and terminal blocks; touchscreen HMI panel mounted on cabinet door or separate pedestal |
| 6 | Run-out Roller Conveyor Table | 3m to 5m free-roller receiving table with height-adjustable legs; collects cut finished sheets for manual stacking and bundling by operator |
| Sequence | Station | What Happens |
|---|---|---|
| 1 | Coil Loading | Steel coil is crane-lifted or coil-car-delivered onto the uncoiler mandrel; hydraulic expansion jaws lock into the coil bore; brake is set to provide controlled strip resistance |
| 2 | Strip Entry | The leading edge of the coil is fed through adjustable side-guide rollers to center it on the machine centerline; a manual pre-shear guillotine trims any bent or uneven coil head stock |
| 3 | Deck Routing | Operator sets the pivoting diverter plate position — upward directs the strip into the IBR forming deck, downward routes it into the corrugated forming deck. Switching between profiles takes approximately 10 minutes |
| 4 | Roll Forming | The flat strip passes through each successive roller station pair; at each station the metal is bent a few degrees further until, by the final station, it has achieved the complete IBR rib geometry or full corrugated wave contour |
| 5 | Length Measurement | A rotary encoder coupled to the last forming shaft sends pulse signals to the PLC; the controller continuously compares accumulated pulse count against the operator-entered target length |
| 6 | Flying Shear Cut | At target length the PLC activates the shear carriage clamp and hydraulic cut cycle; the carriage moves in synchronization with the sheet while the blade executes a clean through-cut; then carriage and blade retract to home position |
| 7 | Panel Offloading | The separated finished sheet slides onto the free-roller run-out table; the operator lifts each panel and stacks it onto a pallet or bundle for storage and dispatch |
| Investment Factor | Two Single-Layer Roll Forming Machines | One Double Layer Roll Forming Machine |
|---|---|---|
| Equipment Capital Cost | 100% baseline (full price of two machines plus two decoilers) | 65–75% of two-machine cost |
| Factory Floor Footprint | 44–70 m² total for both production lines | 20–35 m² including decoiler and run-out table |
| Container Shipping Volume | Two × 20GP containers, double ocean freight cost | Single 20GP or 40HQ container, one freight invoice |
| Civil Works and Power | Two foundation pads, two electrical drops, two cable runs | Single foundation pad, one electrical drop, one cable run |
| Operating Labor per Shift | 3–4 workers across two machines | 1–2 workers for one machine |
| Energy Usage | Two motors and two hydraulic pumps running simultaneously | One motor and one hydraulic pump, approx. 40% less electricity |
| Spare Parts Inventory | Two complete sets of wearing components | One set covers both forming decks |
Before export packaging, every completed roll forming machine passes through a rigorous three-phase quality verification procedure. Phase one is static dimensional inspection: technicians measure every roller gap with calibrated feeler gauges, verify shaft runout with dial indicators at each bearing point, and confirm frame alignment using precision spirit levels and laser measurement tools. Phase two is a minimum four-hour dry run test at maximum rated speed without material — during this run, bearing housing temperatures are monitored at 30-minute intervals with infrared thermometers, chain tension is checked visually and audibly for smooth engagement, and the PLC control system is cycled through all programmed functions including length setting, batch counting, emergency stop, and profile recipe switching. Phase three is a full material trial: factory technicians feed actual galvanized coil stock and produce 50 consecutive IBR sheets followed by 50 consecutive corrugated sheets, measuring length, rib geometry, wave pitch, and cut-edge quality on every 10th panel with calibrated digital instruments. The machine is cleared for shipment only after achieving zero out-of-tolerance results across all three phases.
The main machine body receives a multi-layer protective wrap: first a VCI (volatile corrosion inhibitor) anti-rust film, then foam padding at all corners and protruding parts, followed by heavy-gauge polyethylene shrink wrap. The wrapped machine is bolted to a fumigated plywood pallet or welded steel skid. All ancillary equipment — decoiler, run-out table, hydraulic power unit, and control cabinet — is packed in separate marked wooden crates. A dedicated small crate holds the tool kit, spare parts starter pack, and one complete set of printed technical documentation: mechanical assembly drawings with exploded component views, electrical wiring schematic with terminal block identification, PLC parameter configuration guide, daily and weekly lubrication schedule chart, and the English-language operation and maintenance manual. The entire consignment loads into a single 20-foot GP or 40-foot HQ container. Production lead time is 25–35 working days from confirmed deposit receipt and signed profile drawing approval.
| Optional Item | Purpose and Benefit |
|---|---|
| Servo Motor Drive Retrofit | Replaces standard AC motor with programmable servo drive for precision acceleration control, tighter length tolerance, and reduced energy draw |
| Automatic Pneumatic Stacker | Motorized stacking mechanism lifts finished sheets from the run-out table and arranges them in neat bundles on a pallet, eliminating manual sheet handling labor |
| Powered Coil Loading Trolley | Electric rail-guided cart with hydraulic scissor lift; transports coils from warehouse storage to the uncoiler and lifts them onto the mandrel, handling coils up to 10 tons |
| IoT Remote Monitoring Device | 4G-connected module transmits machine operating hours, daily sheet count, fault alerts, and maintenance reminders to a smartphone app or web dashboard |
| Embossing Roller Insert Set | Custom-engraved roller station that presses a permanent brand logo, production date stamp, or diamond-texture pattern onto each panel during the forming process |
| Stainless Steel Roller Upgrade | Full roller set manufactured from 304 or 316L stainless steel for applications requiring corrosion-proof tooling in food-processing plants, chemical facilities, or marine environments |
