An automatic C purlin roll forming machine is an essential equipment for manufacturing cold roll-formed C and Z purlins from metal coils. This guide provides a comprehensive overview of automatic C purlin roll forming machines, their working, types, applications, specifications, installation, operation, maintenance, suppliers, pricing, pros and cons, and more.
Overview of Automatic C Purlin Roll Forming Machines
C purlins are cold formed sections with a C-shaped cross section used extensively in metal buildings and structures as secondary structural members to support roofing and wall sheeting. Z purlins are similar with a Z-shaped cross section.
Automatic C purlin roll forming machines transform flat metal strips or coils into finished C and Z purlins continuously. They are also known as C/Z purlin rolling mills or C/Z profile roll forming machines.
What is an Automatic C Purlin Roll Forming Machine?
An automatic C purlin roll forming machine takes a flat metal coil strip as raw material and converts it into a continuous formed C or Z purlin using a series of sequential rolling stands. Each rolling stand progressively forms the flat strip into the desired C or Z profile with a reduction in thickness.
The formed purlin gets automatically cut into required lengths by a built-in cutting device. The machine can continuously produce high volumes of finished purlins with a uniform profile and consistent quality.
Main Components
An automatic C purlin rolling mill consists of the following main components:
- Uncoiler: Feeds the flat metal strip from a coil into the forming section
- Forming Stands: Progressively forms the strip into C/Z profile through a series of rolls
- Hydraulic System: Applies pressure to the rolls for forming
- Connecting Conveyors: Joins the stands and transports purlin during forming
- Cutting Device: Cuts the formed purlin at preset lengths
- Control Panel: Controls and monitors the machine operations
How Does an Automatic C Purlin Rolling Mill Work?
An automatic C purlin rolling mill works on the following main steps:
- The flat metal strip is uncoiled and fed into the entry guides
- It passes through a series of rolling stands with forming rolls
- The rolls progressively bend the strip into the C or Z shape by applying pressure
- Hydraulic cylinders regulate the pressure on rolls for calibrated bending
- Connecting conveyors transport the strip through the stands
- Cutting device cuts the formed purlin at required length
- Formed purlins exit the machine automatically
Key Benefits of C Purlin Roll Forming Machines
- Highly automated operation with very less manual intervention
- Continuous and efficient mass production of purlins
- Consistent product quality and dimensional accuracy
- Versatile machines can produce various purlin profiles
- Lower operating costs compared to other forming methods
- Minimal material wastage due to optimized nesting during cutting
- Flexible production volumes based on speed and coil width
- Safer working compared to manual bending methods
Types of Automatic C Purlin Rolling Mills
Automatic C purlin roll forming machines are available in different types based on design, size, production volumes, level of automation, and specialized features.
Based on Automation Level
- Manual: Require manual feeding and cutting of strips
- Semi-Automatic: Automated forming but manual strip feeding and cutting
- Fully Automatic: Automated strip feeding, forming and cutting
Based on Production Capacity
- Low Output: Up to 10 tons/hour
- Medium Output: 10 – 20 tons/hour
- High Output: Above 20 tons/hour
Higher output mills have heavier duty construction, bigger motor sizes, and additional features to handle higher volumes.
Based on Specialized Features
- Fly Shear Type: Cuts purlins during forming without stopping production
- Servo Motor Type: Utilizes servo motors for speed and power control
- IoT Enabled: Allow real-time monitoring and data analysis via internet
- Customized: Tailor made machines for specific purlin profiles
Applications and Use of C Purlin Roll Forming Machines
Automatic C purlin roll forming mills have a wide range of applications in manufacturing metal building components:
Key Applications
- Producing C purlins up to 12m length for roofing and walls
- Manufacturing Z purlins for cladding support in buildings
- Rolled C sections for mezzanine floors and platforms
- Lightweight C columns for interior structures
- Sturdy C beam supports in factories, warehouses, garages
- C channel frames for machinery brackets and bases
| Purlin Type | Typical Uses |
|---|---|
| C Purlins | Roofing, walls, mezzanines, platforms |
| Z Purlins | Roofing, cladding, wall supports |
| C Sections | Columns, beams, frames, channels |
Industries Served
C purlin roll forming mills serve a range of industries involved in metal building construction:
- Metal building manufacturers
- Construction contractors
- Modular building makers
- Steel fabricators
- Warehouse builders
- Industrial shed contractors
- Commercial builders
This versatile equipment produces secondary structural members supporting roofing, siding, wall panels which are ubiquitous in metal building assemblies.
Specifications and Design of C Purlin Rolling Mills
C purlin roll forming machines are available in different specifications based on production needs. Key technical parameters are:
Machine Specifications
| Parameter | Typical Range |
|---|---|
| Production Speed | 10-45 m/min |
| Output Capacity | 10-100 tons/hour |
| Roller Diameter | Φ220-Φ320 mm |
| Number of Stands | 18-24 |
| Forming Stands Gap | 600-1200 mm |
| Purlin Width | 100-300 mm |
| Purlin Height | 80-240 mm |
| Metal Thickness | 0.4-1.6 mm |
| Power Consumption | 11-75 KW |
Machine Dimensions
| Dimension | Range |
|---|---|
| Line Length | 10-30 m |
| Machine Height | 1.6-2.2 m |
| Machine Width | 2.2-3 m |
| Weight | 8-15 tons |
Length, height, and output directly correlate to the production capacity. Larger high-output mills have bigger footprint and height.
Key Design Standards
- Use thicker 2-3mm steel plate for machine frame and stands
- Utilize rigid boxes instead of open C frames for robust construction
- Higher bearing centers for stable material transfer
- Optimize roller diameters between Φ250-Φ320mm
- Hardened gears and pinions for long working life
- Centralized lubrication system for ease of oiling
- Ergonomic control panel placement for visibility
Safety Features
- Fully enclosed body and moving parts
- Sensors to stop machine if covers are opened
- Emergency stop buttons in control panel
- Overload protection for motors
- Low voltage controls for operator safety
- Warning decals on high voltage parts
Installation and Commissioning
Proper installation and commissioning of the C purlin rolling mill is crucial for smooth functioning. Below are the key steps:
Site Preparation
- Ensure the foundation is leveled, rigid and can withstand vibrating loads
- Have adequate space around machine for material movement
- Keep sufficient vertical clearance for folding the covers during maintenance
- Install power lines with appropriate voltage and breakers
- Set up hydraulics, coolants, and lubrication supply lines
Positioning and Leveling
- Use thick steel plates under machine frame to evenly distribute weight
- Carefully position the stands in sequence and couple shafts
- Align stands with precision using a theodolite or laser level
- Adjust leveling bolts to ensure perfect horizontal alignment
- Couple gearboxes, motors, and drive connections
Trial Runs
- Check direction of motors and hydraulic power packs
- Give trial runs without load to test functioning of all parts
- Fix any issues with alignments, drive connections, or sensors
- Under supervision, run machine with dummy coils at 50% speed
- Increase speed in steps up to maximum rated capacity
- Confirm properly formed profiles and smooth functioning
Operation and Working of C Purlin Rolling Mills
Operating a C purlin roll forming machine involves systematic procedures for setup, changeovers, run, maintenance, and troubleshooting.
Machine Setup
- Input specifications of purlin profile and dimensions
- Calculate roll pass sequences and adjust forming rolls
- Set hydraulic pressure for stand gaps based on metal thickness
- Install new tooling pieces if needed for profile change
- Set length control parameters in the control system
Material Loading
- Bring required metal coils of proper width via crane or forklift
- Attach coil mandrel through the eye and secure it to the reel stand
- Feed metal strip into entry guides from the decoiler
Starting Production
- Set run speed on the control panel and engage drive motors
- Initiate automatic operation and monitor strip feeding
- Allow few defective parts in initial run until process stabilizes
- Ensure proper forming of profile through the rolling stands
- Check if cut sections are of desired length
Changeover Procedure
- Stop machine and remove residual coils strips manually
- Change forming rolls and tooling parts to new profile
- Adjust roll gaps and pressure settings
- Run at lower speed to check new profile formation
- Resume full production after quality approval
Routine Maintenance
- Lubricate all bearings and moving joints daily
- Check sensors, controls, and oil levels periodically
- Watch for any abnormal noise or heating
- Replace damaged/worn out parts before failure
- Monitor roll and gear wear periodically
Troubleshooting Issues
- Profile distortion issues – adjust roll gaps
- High scrap percentage – check forming roll design
- Uneven cutting length – reset/replace length controller
- Excessive vibration – realign stands/supports
- Hydraulic oil overheating – inspect pump and cylinders
- Motor overload tripping – correct alignment and lubrication
Suppliers and Pricing of C Purlin Roll Forming Machines
There are many equipment manufacturers and suppliers providing automatic C purlin roll forming mills. Buyers need to shortlist suppliers based on reputation, local presence, service support, prices, and financing options.
Manufacturers and Suppliers
Some leading global suppliers of C purlin roll forming equipment are:
- METFORM
- Ermis
- Gasparini
- Dimeco
- ASC Profiles
- Hellweg Maschinenbau
- Durma
- Setex Textiles
Cost Considerations
- Machine Cost: $50000 – $150000 depending on output and automation level
- Shipping Charges: 10-15% for international transportation
- Import Duties & Taxes: 15-25% in certain regions
- Installation & Commissioning: $3000 upwards depending on complexity
- Spare Parts Inventory: ~10% of machine cost recommended
| Estimated Price Range | |
|---|---|
| Manual and Semi-Automatic Mills | $55000 – $95000 |
| High Output Fully Automatic Mills | $100000 – $150000 |
| Large Sized HD Mills > 30 tons/hr | Above $200000 |
Pricing also depends on options like decoilers, stackers, runout tables, and other accessories chosen. Request itemized quotes from shortlisted suppliers.
Payment Terms
- 30% advance payment common
- 60% before shipment via wire transfer
- 10% after installation and commissioning
- Confirmed letters of credit ensure payment security
How to Select the Right C Purlin Roll Forming Machine?
Choosing the appropriate automatic C purlin rolling mill requires aligning machine capabilities to the buyer’s production requirements, site conditions, and budget.
Key Selection Criteria
- Required output: Match to machine capacity in tons/hr
- Purlin dimensions: Check machine allows required purlin widths and thicknesses
- Level of automation: Decide based on labor costs and productivity goals
- Production speed: Ensure machine achieves the speeds you need
- Power supply: Match to machine electrical requirements
- Production scale: Size initial investment based on current and future volumes
- Site conditions: Consider space, foundations, accessibility
- Safety features: Must have all essential safety mechanisms
- Local support: Ensure good after-sales technical support
- Supplier reputation: Choose reputable manufacturers for quality assurance
Evaluation Process
- Determine production requirements and specifications
- Research equipment capabilities and suppliers
- Shortlist 2-3 suppliers and get detailed quotes
- Review technical specs against requirements
- Compare pricing and warranty terms
- Check client references and supplier reputation
- Visit facilities of shortlisted suppliers if possible
- Select supplier providing the best value proposal
- Negotiate optimal pricing and payment terms
Pros and Cons of Automatic C Purlin Rolling Mills
Advantages
- High production rates up to 100 tons/hour
- Low operating costs due to automation
- Consistent product quality and tolerances
- Uniform material properties by cold rolling
- Adaptable to produce various purlin profiles
- Lower scrap loss compared to other methods
- Safer operation with reduced manual handling
- Better working conditions without hot processes
Limitations
- Significant initial capital investment required
- Complex machinery requiring skilled maintenance
- Large space requirement for installation
- Limited flexibility for short production runs
- Difficult profile changes compared to press brakes
- Not suitable for small to medium scale needs
- Rolls have wear and tear with use over time
Conclusion
Automatic C purlin roll forming mills offer an efficient solution for mass producing cold-formed structural C and Z purlins from metal coils. With high outputs of up to 100 tons per hour, these machines enable metal building product manufacturers to meet high volume demands cost-effectively while maintaining consistent quality and tolerances.
While the initial equipment investment is significant, the automation, speed, and reliability of these mills help reduce operating costs and improve productivity considerably in the long run. With a properly sized machine from a reputable supplier, buyers can leverage automatic C purlin rolling mills to gain a competitive advantage in construction product markets.
FAQ
Q: What metals can be formed into C purlins using these machines?
A: Most commonly low carbon steel, galvanized steel, and galvalume coils are used for roll forming C purlins. Aluminum coils can also be formed into lightweight purlin sections.
Q: What thicknesses of metal can these mills handle?
A: Standard machines can typically process metal coils of thickness between 0.4mm to 1.6mm. Heavy duty mills are available to form thicker coils up to 3mm.
Q: What tolerances can be achieved for the purlin dimensions?
A: Roll formed C purlins using these machines can consistently achieve dimensional tolerances of +/- 1.0mm for web depth and +/- 0.5mm for flange widths.
Q: How often must the forming rolls be changed or refurbished?
A: Forming rolls require reshaping or hardfacing after processing approximately 25,000 to 40,000 tons of metal. Proper use and maintenance can maximize roll life.
Q: Should buyers purchase new machines or second hand equipment?
A: For the long term, investing in a new machine from a reputable manufacturer is advisable for most buyers. Used or rebuilt equipment can be considered by highly skilled technicians for cost savings.
Q: What safety tests are required for these machines during commissioning?
A: Standard safety checks include proper functioning of emergency stop, light curtains, door interlocks, overload relays, insulation resistance, earth bonding, and functional tests.