Leading Roll Forming Machine Factories

 

Roll forming is an efficient, continuous process for producing parts with long uniform cross-sections. The roll forming machine is the heart of the production line that shapes sheet metal coil into desired profiles using a series of roller dies.

 

Choosing a dependable roll former OEM factory is crucial for getting capable equipment, prompt after-sales support and value for investment.

 

This guide covers major roll forming machine manufacturers across geographies, their offerings, strengths and selection factors for partnership.

 

 

Overview Of Roll Forming Process

 

Roll forming works by passing sheet or coil stock through consecutive roller die stands which apply incremental cold forming until the final shape is achieved. Common roll formed profiles include roofing panels, racks, door sections and electronic enclosures.

 

Figure 1: Roll forming progression from flat strip to finished part

 

The advantages of roll forming are fast production, efficient raw material utilization, flexibility for automation and low tooling maintenance over long runs.

 

Types Of Roll Forming Machines

 

Roll formers come in different configurations based on production needs:

 

Table 1: Major Roll Forming Machine Types

 

Machine Type	Description	Typical Applications
In-line Roll Former	Uncoiler-feed straight into forming-cutoff line	High volume long production runs
Reversible Roll Former	Reversing rollers to return sheet through dies	Low volume applications, save space
Portable Roll Former	Compact on wheels for mobility	On-site production requirements
Custom Roll Former	Engineered for specialized profiles	Unique proprietary cross-sections

In addition to working width and forming length, options like number of die stations, level of automation, secondary operation capability and software flexibility differentiate machine models.

 

Top Roll Forming Machine Factories

 

Some leading global OEMs with decades of expertise in roll former engineering are:

 

Dimeco – USA

 

Key Models: Helios, UltraFab, MaxxForm

 

Dimeco is a major American roll forming equipment brand with over 50 years of know-how. Key strengths include:

 

• Modern plant infrastructure and stringent quality norms
• High end automation options like robotic part handling
• R&D investments in IoT for data-driven improvements
• Responsive technical support through trained representative network

 

They offer the latest solutions like the Helios series with smart IoT connectivity for predictive maintenance and production monitoring.

 

Gasparini – Italy

 

Key Models: FlexyRoll, FastRoll, ServRoll

 

Gasparini from Italy has over 60 years of industry presence. They focus on speed and flexibility:

 

• High speed production at >100 ft/min
• Quick change-over modular tooling
• Easy integration of secondary operations
• Advanced software for efficient changeovers

 

Gasparini’s FlexyRoll range offers versatile roll solutions paired with intelligent production management capabilities.

 

Formtek – Canada

 

Key Models: Orion, Maxima, Optimax

 

With over 25 years of specialization, Canadian brand Formtek provides made-to-order forming solutions. Their advantages include:

 

• Custom engineering of roll formers
• Precision quality assurance over the full process
• Niche finishing solutions through partner networks
• Roll design simulation software for optimal equipment builds

 

They are experts in tailoring solutions from scratch based on customer needs via their proprietary simulation and controls software.

 

Bradbury Group – USA

 

Key Models: SelectRoll, EasyForm, Pro-Formpak

 

The Bradbury Group have been pioneers in pioneering roll forming for over 70 years. Their strengths lie in:

 

• High-end fully customized roll solutions
• Integrated extrusion and embossing modules
• Specialists in high speed thin gauge production
• Extensive spare part inventory and field service crew

 

Bradbury’s SelectRoll models paired with Pro-Formpak software offer high efficiency automation.

 

 

Comparison Of Top Roll Former Producers

 

Table 2: Leading Roll Forming Machine Brand Comparison

 

Manufacturer	Location	Roll Models	Price Range	Max. Speed	Strengths	Limitations
Dimeco	USA	Helios, UltraFab	$150k to $500k	80 ft/min	Automation, IIoT connectivity	Complex shapes capability
Gasparini	Italy	FlexyRoll	$250k to $1 Mil	100 ft/min	High speed forming	Inline secondary ops
Formtek	Canada	Orion, Optimax	$100k to $800k	60 ft/min	Custom engineering	Budget automated lines
Bradbury	USA	SelectRoll	$150k to $600k	120 ft/min	Thin gauge high speed	proprietary electronics

Evaluate manufacturers against production targets, quality, customization ability and service infrastructure.

 

Inside A Roll Forming Machine Factory

 

Modern roll former OEM factories leverage the latest infrastructure for quality and productivity. Here is what the shopfloor typically looks like:

 

Key Sections:

 

• Fabrication – Where structural frames, gears, guards etc. are made
• Sub Assembly – Gear stands, conveyors etc. are built up
• Machining – Where roller dies, shafts, blades are CNC machined
• Assembly – Where machines are integrated and wired
• Testing and Validation – Where roll ops are verified before dispatch
• Automation Focus – Robots, conveyor systems for material Handling
• Quality Checks – Laser alignment, dimensional checks using CMMs
• Flexibility – Modular builds, quick changeovers

 

The layout is optimized for efficient material and information flows across interconnected work stations.

 

Ancillary Equipment With Roll Forming Lines

 

Often customized secondary operation stations are integrated in the production line:

 

Table 3: Common Roll Forming Line Ancillary Equipment

 

Machine	Role	Method
Embossing press	Imparts raised textures and logos	Stamping dies
Hole punch	Create lightening holes and hardware slots	Punch and die set
Shear/slitter	Longitudinal cut for width control	Rotary shear blades
Decoilers	Alternative coil holding and feeding	Motorized tension regulated unwind stands
Ink marking	Printing date stamps, barcodes etc.	Inkjet digital printer
Panel bender	Add transverse bends for ducts	Adjustable snap folders

These help impart additional features or functionality to roll formed base profiles.

 

Testing Standards At Roll Former Factories

 

To prove performance key tests are conducted:

 

• Dimensional checks – Using height gauges and CMMs
• Bend quality – By measuring formed angles and observing for defects
• Speed trials – Testing at high feeds for continuous runs
• Overload – Stressing dynamic components close to peak capacity
• Environmental – Temperature, humidity, vibration testing
• Field evaluations – Beta testing at customer plants before final design sign-off

 

Extensive prototyping validates capability prior to releasing production grade machines.

 

Global Certification Standards

 

Reputed factories comply with:

 

• ISO 9001 – Quality Management System
• ISO 14001 – Environmental Management System
• OHSAS 18001 – Occupational Health and Safety Assessment

 

This ensures they meet the highest organizational, manufacturing and sustainability benchmarks.

 

 

Choosing Your Roll Forming Machine Partner

 

Aspects to evaluate when shortlisting manufacturers:

 

Table 4: Roll Former OEM Selection Criteria

 

Parameter	Guidelines
Experience	Number of years in business
Domain Knowhow	Understands nuances your specific product needs
Quality Focus	Stringent norms, global certifications
Delivery Record	History of on-time, on-quality execution
Customization Skills	Ability to customize for special needs
Service Infrastructure	Trained technicians, adequate spare part stocks
Pricing and Value	Price commensurate with quality and features

Interact with multiple vendors in detail to choose the best fit for needs.

 

Summary

 

Partnering with an expert roll forming machine factory with proven technology, quality and support credentials ensures access to robust equipment that delivers productivity with precision. Invest time to clearly outline production requirements and evaluate supplier strengths on all aspects. This guide covered leading international OEMs like Dimeco, Gasparini and Formtek along with capabilities to look for. Leverage the latest innovations in roll forming for maximizing output.

 

know more Roll forming