helen@hbxinnuorollforming.com
Produces two metal roof profiles from one compact production machine
Upper deck forms trapezoidal rib roofing lower deck forms wave roofing
PLC digital controller programs roof panel length and batch quantity
Hydraulic flying shear cuts metal roof panel at programmed target length
Chrome plated rollers protect galvanized coating during roof making process
Heavy steel welded frame with post-weld thermal stress relief treatment
Complete metal roof production line shipped in single export containerProduces two metal roof profiles from one compact production machine
Upper deck forms trapezoidal rib roofing lower deck forms wave roofing
PLC digital controller programs roof panel length and batch quantity
Hydraulic flying shear cuts metal roof panel at programmed target length
Chrome plated rollers protect galvanized coating during roof making process
Heavy steel welded frame with post-weld thermal stress relief treatment
Complete metal roof production line shipped in single export container
This double layer metal roof making machine is engineered to manufacture two different metal roof panel profiles from one integrated production unit. The machine houses two complete roller forming decks within a single welded structural steel frame — enabling metal roofing manufacturers to produce both corrugated wave roof panels and IBR (Inverted Box Rib) trapezoidal roof panels without purchasing and maintaining two separate production lines. The lower forming deck produces traditional corrugated metal roof panels — the classic sinusoidal profile that remains the most widely consumed affordable roofing material in developing construction markets worldwide. The upper forming deck produces IBR trapezoidal metal roof panels — a structural roofing profile with deep stiffening ribs that provides superior span strength and weather performance for industrial warehouses, commercial buildings, and cyclone-resistant construction.
| Roof Panel Characteristic | Corrugated Wave Roof Panel | IBR Trapezoidal Roof Panel |
|---|---|---|
| Profile Cross-Section Shape | Continuous sinusoidal wave with uniform curvature | Deep trapezoidal ribs separated by flat valley floor sections |
| Finished Roof Panel Width | 660mm to 1000mm effective coverage | 762mm to 1100mm effective coverage |
| Profile Depth Measurement | 12–18mm wave crest-to-trough amplitude | 28–43mm rib crown height above valley plane |
| Waves or Ribs per Panel | 5, 7, 9, or 11 sinusoidal waves | 4, 5, or 6 trapezoidal stiffening ribs |
| Panel Length Production Range | 1.0m to 14.0m per roof panel | 1.0m to 14.0m per roof panel |
| Primary Roof Application | Residential housing, farm buildings, community structures, perimeter fencing | Industrial warehouses, commercial complexes, cyclone-resistant buildings, school halls |
| Span Performance Between Purlins | Up to 2.5m spacing under standard conditions | Up to 4.5m spacing in standard wind zones |
| Side Joint Weather Sealing | 1.5-wave minimum overlap for weathertight joint | Single overlap with optional anti-capillary groove seal |
| Production Phase | Station Reference | Metal Forming Action |
|---|---|---|
| Strip Reception and Alignment | Station 1 | Flat galvanized steel strip enters from the hydraulic decoiler at regulated feed tension. The first roller pair receives and laterally constrains the strip, establishing the roof panel centerline axis. Initial edge flange turning begins as the material enters the roof making sequence |
| Profile Bend Initiation | Stations 2–5 | Profile-specific roller contours apply gentle bending force at the exact positions where corrugated wave crests or IBR ribs will develop. Approximately 5–10 degrees of angular change per station. The metal stays within its safe forming limits, preventing damage to the galvanized zinc coating layer |
| Progressive Profile Development | Stations 6–12 | Wave troughs deepen and crests sharpen for corrugated roof panels; rib side walls steepen and valleys flatten for IBR roof panels. Seven consecutive stations distribute total deformation evenly, achieving uniform material flow that preserves consistent panel gauge thickness across all bent profile areas |
| Final Roof Panel Geometry | Stations 13–16 | The last active forming rollers set the finished roof panel dimensions — wave amplitude and pitch spacing for corrugated output; rib crown height, valley base width, and side lap geometry for IBR output. Springback compensation is engineered into the roller profiles to ensure the produced roof panel retains its design dimensions |
| Quality Calibration Pass | Stations 17–18 | A final sizing roller pair eliminates any residual dimensional deviation. At this stage the metal roof panel has achieved its complete engineered profile, verified to within ±0.5mm of the specification drawing across the full cover width |
| Tooling Feature | Corrugated Roof Panel Deck | IBR Roof Panel Deck |
|---|---|---|
| Roller Station Quantity | 13–16 pairs of upper and lower forming rollers | 14–18 pairs of upper and lower forming rollers |
| Roller Raw Material | 45# medium carbon forged steel billet; ultrasonic tested for internal integrity before CNC machining | 45# medium carbon forged steel billet; ultrasonic tested for internal integrity before CNC machining |
| CNC Profile Machining Accuracy | Contour turning on CNC lathe; sinusoidal wave geometry within ±0.05mm tolerance | Contour turning on CNC lathe; trapezoidal rib geometry within ±0.05mm tolerance |
| Heat Treatment Process | Controlled-atmosphere gas carburizing furnace; oil quench hardening; surface HRC 58–62; tough ductile core retained | Controlled-atmosphere gas carburizing furnace; oil quench hardening; surface HRC 58–62; tough ductile core retained |
| Chrome Surface Plating | Industrial hard chrome electrodeposition; 0.05mm minimum thickness; mirror-grade polished surface finish | Industrial hard chrome electrodeposition; 0.05mm minimum thickness; mirror-grade polished surface finish |
| Drive Shaft Specification | Φ75–Φ80mm 40Cr alloy steel bar; precision ground to h7 tolerance class; keyway for drive sprocket | Φ75–Φ80mm 40Cr alloy steel bar; precision ground to h7 tolerance class; keyway for drive sprocket |
| Bearing Assembly Type | Split cast iron pillow block; double-row self-aligning spherical roller bearing; Zerk grease lubrication fitting | Split cast iron pillow block; double-row self-aligning spherical roller bearing; Zerk grease lubrication fitting |
| Machine System | Engineering and Construction Detail |
|---|---|
| Welded Structural Frame | Heavy channel steel longitudinal beams and cross-braced H-beam vertical columns in 300H–400H structural grade steel. Complete chassis undergoes post-weld thermal stress-relief annealing in an industrial furnace to neutralize all residual fabrication stresses. Following heat treatment, every bearing mounting pad is precision machined to guarantee absolute shaft axis parallelism across all roller stations in both roof panel forming decks |
| Motor and Gearbox Drive | 5.5kW or 7.5kW AC induction motor (4-pole, IP54 enclosure) coupled to a worm-type dual-output shaft speed reducer with oil-bath lubrication. Reduction ratios: 1:40 for faster thin-gauge roof panel production or 1:59 for higher-torque thick-gauge processing. Each output shaft independently powers one complete roof panel deck through a dedicated heavy-duty double-row industrial roller chain circuit with hardened alloy sprockets and individual chain tension adjustment per loop |
| Hydraulic Panel Cutting Unit | 4.0kW gear pump motor with 80L oil reservoir, inline filtration, sight glass level indicator, and temperature monitor. Flying shear carriage on precision linear guide rails with pneumatic roof panel clamp. Cr12MoV cold-work die steel blade set vacuum heat treated to HRC 60–64, profile-ground to match the roof panel cross-section for clean cuts that preserve panel geometry |
| PLC Digital Control System | Programmable logic controller (Siemens S7-1200, Delta DVP, or Mitsubishi FX3U per order) with VFD inverter for stepless roof production speed regulation. 7-inch or 10-inch color touchscreen HMI with multi-language display and recipe storage memory. Rotary pulse encoder on final forming shaft provides real-time panel length measurement with digital feedback to the PLC auto-correction algorithm. Safety features: mechanical limit switches at shear carriage positions plus three emergency stop pushbuttons along the production line |
| Pos. | Equipment | Function in Metal Roof Making |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Holds the raw steel coil on expanding hydraulic jaws rated for 5-ton or 8-ton capacity. Adjustable brake system maintains uniform strip pay-off tension for consistent roof panel quality from beginning to end of each coil |
| 2 | Entry Guide and Pre-Shear Table | Adjustable side guide rollers center the incoming strip on the machine centerline. Integrated manual guillotine blade squares the coil leading edge before threading into the selected roller deck for roof panel production |
| 3 | Double Layer Main Roof Making Machine | Central production unit with lower corrugated roof panel deck and upper IBR roof panel deck in one welded frame. Pivoting diverter plate directs strip into the active deck. Both decks share the drive motor, gearbox, chain circuits, hydraulic shear, and PLC controller |
| 4 | Flying Hydraulic Post-Cut Shear | On cut command from PLC, shear carriage accelerates to match line speed; pneumatic clamp secures the formed roof panel; hydraulic cylinder drives the profiled blade through the cross-section; carriage and blade retract to home — complete cycle executed without interrupting continuous roof panel production |
| 5 | Digital Electrical Control Enclosure | IP54 rated steel cabinet housing PLC processor, VFD inverter, motor contactors, overload protectors, circuit breakers, and terminal blocks. External color touchscreen HMI for panel length programming, batch counting, speed adjustment, and fault diagnostics |
| 6 | Roof Panel Discharge Conveyor | 3m–5m free-roller receiving table with height-adjustable legs. Catches finished roof panels exiting the shear and provides a stable platform for manual stacking, bundling, and transport to finished goods storage |
| Specification Item | Technical Data |
|---|---|
| Compatible Coil Materials | Hot-dip galvanized steel (zinc coating Z60–Z275 g/m²), pre-painted galvanized iron (PPGI with PE/SMP/PVDF topcoat), aluzinc/Galvalume (AZ150–AZ200), cold-rolled steel strip, aluminum alloy coil (1100 and 3003 series) |
| Roof Panel Material Thickness Range | 0.25mm to 0.80mm (approximately gauge 30 through gauge 20 equivalent) |
| Material Yield Strength Capability | 200 MPa to 400 MPa covering standard mild steel through high-tensile structural grades |
| Roof Panel Production Speed | 10–18 linear meters of finished roof panel per minute; infinitely variable speed via VFD inverter control |
| Panel Cut Length Precision | ±1.0mm at any programmed roof panel length via rotary encoder digital pulse feedback to PLC auto-correction logic |
| Roof Profile Changeover Method | Manual pivoting material diverter plate; switch from corrugated to IBR roof panel production in approximately 10–15 minutes including strip re-threading |
| Electrical Power Supply | 380V 50Hz 3-phase standard; custom voltage (220V/415V/440V/480V) and frequency (50/60Hz) per destination country grid |
| Total Installed Motor Power | Approximately 10–12 kW (main drive 5.5/7.5kW + hydraulic pump 4.0kW combined) |
| Machine Overall Dimensions | Approximately L 7.0–8.0m × W 1.4–1.6m × H 1.7–2.0m according to ordered roller station count and frame grade |
| Machine Net Shipping Weight | 5.0 to 7.5 metric tons depending on profile configuration, roller count, and frame specification |
| Uncoiler Coil Capacity | 5 metric tons standard duty or 8 metric tons heavy duty per customer production volume requirement |
| Coil Inner Bore Diameter | Φ508mm industry standard; Φ610mm available with uncoiler mandrel adapter sleeve |
| Step | Operation Stage | Operational Description |
|---|---|---|
| 1 | Coil Loading | Raw steel coil positioned onto the hydraulic uncoiler mandrel using overhead crane or coil cart. Hydraulic expansion jaws engage and lock the coil bore. Brake resistance set to deliver uniform strip feed tension throughout the production run |
| 2 | Strip Entry and Alignment | Coil leading edge threaded through adjustable entry side guide rollers for centerline alignment. Manual pre-shear guillotine squares the coil head before strip enters the selected roller deck for roof panel production |
| 3 | Roof Profile Deck Selection | Operator positions the pivoting diverter plate — downward for corrugated roof panel production on the lower deck; upward for IBR roof panel production on the upper deck. Profile changeover takes approximately 10 minutes |
| 4 | Progressive Roll Forming | Flat steel strip advances sequentially through each roller station pair. At every station the metal receives incremental bending deformation until the final station delivers a complete corrugated wave roof panel or finished IBR trapezoidal roof panel ready for length cutting |
| 5 | Panel Length Measurement | Rotary pulse encoder on the final drive shaft sends continuous digital signals to the PLC. The controller compares real-time accumulated pulse count against the operator-programmed target roof panel length |
| 6 | Automated Panel Cutting | At target length the PLC triggers the cut sequence: pneumatic clamp grips the formed roof panel → shear carriage accelerates to match line speed → hydraulic cylinder drives the Cr12MoV blade through the panel cross-section → blade and carriage retract to home — cut cycle completes without stopping roof panel production |
| 7 | Roof Panel Stacking | The separated finished roof panel slides onto the discharge roller conveyor. Operator lifts each panel and stacks onto the product pallet or bundle for strapping, warehousing, and delivery to construction customers |
| Investment Category | Two Separate Roof Making Machines | One Double Layer Roof Making Machine |
|---|---|---|
| Equipment Capital Outlay | 100% — total purchase cost of two complete machines plus two uncoilers | Approximately 65–75% of the two-machine combined price |
| Factory Floor Space Required | 44–70 square meters for both production lines | 20–35 square meters for one dual-output line |
| Ocean Container Shipping Cost | Two 20GP containers, two separate freight invoices | One 20GP or 40HQ container, single consolidated freight invoice |
| Foundation and Utility Installation | Two concrete machine pads, two power drops, two cable runs | One concrete machine pad, one power drop, one cable run |
| Production Workforce per Shift | 3–4 operators across two independent lines | 1–2 operators for one dual-deck production line |
| Monthly Electricity Expense | Two drive motors and two hydraulic pumps drawing power | One motor and one pump — approximately 40% lower monthly cost |
| Spare Wearing Parts Inventory | Two complete sets in warehouse stock | One spare parts kit services both roof panel decks |
Before export crating, every completed metal roof making machine must pass a rigorous three-phase quality verification protocol. Phase one — comprehensive dimensional inspection: all roller gaps at every forming station are measured with calibrated feeler gauges against the engineering tolerance specification; shaft concentricity runout is verified at all bearing positions with dial test indicators; frame alignment and squareness are confirmed using precision spirit levels and cross-laser instruments. Phase two — extended no-load operational test: the machine operates continuously at maximum rated roof production speed without material for a minimum of four hours; bearing temperatures are monitored and recorded at 30-minute intervals using infrared thermometers; chain drive engagement is inspected visually and audibly for smooth sprocket meshing; every PLC function undergoes validation including power-up, motor start-stop, speed regulation, panel length programming, batch quantity setting, recipe storage and recall, emergency stop activation, and restart — confirming complete system integration. Phase three — live roof panel production trial: factory technicians load genuine galvanized steel coil and produce 50 consecutive corrugated roof panels plus 50 consecutive IBR roof panels; every 10th panel is measured for length, wave pitch or rib geometry, and cut edge quality using calibrated digital instruments. Only machines achieving zero out-of-tolerance results across all three phases receive export packaging approval.
The main roof making machine body receives comprehensive multi-layer protective export packaging: an inner wrap of VCI anti-rust film; a middle layer of high-density closed-cell foam padding at all corners, machined surfaces, and protruding components; an outer wrap of heavy-gauge UV-stabilized polyethylene shrink film for moisture, dust, and handling protection. The wrapped assembly is bolted to a fumigated ISPM-15 certified plywood pallet or welded steel export skid. The hydraulic uncoiler, discharge roller conveyor, hydraulic power pack, and electrical control enclosure are packed individually in purpose-built marked fumigated wooden crates with internal foam bracing and bolted tie-downs. A dedicated accessories crate contains the operator tool kit, spare wearing parts starter pack, and a complete printed technical documentation set: mechanical assembly drawings with exploded views, electrical wiring schematic with terminal labeling, PLC parameter configuration guide, lubrication schedule with recommended grease specifications, and the comprehensive English-language operation and maintenance manual. Standard manufacturing lead time is 25–35 working days from deposit receipt and customer-signed profile approval drawings. Standard warranty coverage is 12 months from the bill of lading date.
| Optional Enhancement | Description and Operational Benefit |
|---|---|
| Servo Motor Drive System | Replace standard AC motor with programmable servo drive for controlled acceleration and deceleration profiles, enhanced panel length accuracy, and reduced energy consumption during intermittent roof production cycles |
| Automatic Roof Panel Stacker | Motorized stacking arm transfers finished roof panels from the discharge conveyor to neatly aligned bundles on a pallet, eliminating manual handling labor and reducing operator fatigue during long production shifts |
| Electric Coil Transport Trolley | Battery-powered cart on floor-mounted guide rails with hydraulic scissor lift; transports steel coils up to 10 tons from storage to the uncoiler mandrel without overhead crane dependency |
| IoT Remote Production Monitoring | 4G cellular-connected module transmits real-time roof production data — daily panel output, motor operating hours, fault codes, and maintenance interval alerts — to a smartphone app or web dashboard |
| Custom Embossing Roller Station | Specially engraved forming roller that permanently imprints a brand name, logo, or batch code into each roof panel during the production process for product identification and market recognition |
| Stainless Steel Roller Upgrade | Complete roller set in grade 304 or 316L austenitic stainless steel for roof panel production in food-grade facilities, pharmaceutical plants, chemical environments, or high-salinity coastal locations |
Hebei Xinnuo is a professional cold roll forming machinery manufacturer with 20+ years of experience. We specialize in C/Z purlin machines, roof panel roll formers, floor deck machines, and custom profile solutions — exported to 50+ countries worldwide.
