Overview
A shutter door roll forming machine is used to manufacture shutter doors and shutters for windows, doors, and other openings. It forms metal coil into various shutter door profiles through a series of progressive roll forming stations.
Key details about shutter door roll forming machines:
- Equipment type: Roll forming machine
- Materials processed: Metal coils, typically galvanized steel or aluminum
- Finished products: Shutter doors, louvre shutters, rolling shutters
- Forming method: Roll forming
- Automation: Fully automatic PLC controlled machine
- Capacities: Up to 18 meters per minute forming speed
- Popular sizes: 0.5 mm to 1.2 mm thickness coils, up to 1250 mm width
Shutter Door Roll Forming Machine Types
| Machine Type | Description |
|---|---|
| C Shutter Profile Machine | Produces C-shaped profiles with return lips for strength |
| U Shutter Profile Machine | Forms U-shaped channels as the shutter frame |
| Double Layer Roll Former | Creates shutters with insulation layer sandwiched between two skins |
| Perforated Shutter Machine | Punches decorative and functional holes into the shutter sheets |
| Curtain Roll Former | Rolls aesthetic curtain-type profiles for cafe shutters |
| Rolling Shutter Machine | Forms interlocking slats for overhead rolling doors |
Shutter Profiles Produced
| Profile Shape | Features | Applications |
|---|---|---|
| C Shutter Profile | C shaped with return lips Simple and strong Efficient use of metal | Interior, exterior shutters Fire rated, hurricane shutters Insulated, soundproof shutters |
| U Shutter Profile | U channel shape Lightweight but rigid Sleek modern look | Interior decorative shutters Cafe style foldable shutters |
| Double Layer Profile | Insulating air gap Energy efficient Noise reduction | Exterior shutters Climate control shutters Soundproofing shutters |
| Perforated Profile | Decorative holes Allows light/air flow Unique visual effects | Interior designer shutters Outdoor privacy screens Decorative dividers |
| Curtain Profile | Interlocking curtain look Accordion fold style Flexible openings | Cafe shutters Room dividers Adjustable partitions |
| Rolling Shutter Profile | Interlocking articulated slats Lift up and roll up Security and storm protection | Shopfront shutters Garage doors Retractable gates |
Shutter Door Roll Former Specifications
| Parameter | Typical Range |
|---|---|
| Forming Speed | 10 – 18 m/min |
| Forming Stations | 20 – 30 |
| Forming Rolls | 40 – 60 |
| Thickness Capacity | 0.5 – 1.2 mm |
| Width Capacity | Up to 1250 mm |
| Coil Weight Capacity | Up to 3000 kg |
| Motor Power | 5.5 – 11 kw |
| Machine Weight | 8000 – 15000 kg |
| Machine Size | 10 – 15 m long x 2 – 3 m wide x 2 – 2.5 m high |
Design and Construction
- Heavy welded steel frame and base for stability
- Precision machined forming rolls mounted on shafts
- Roll shafts supported on sturdy bearings
- Adjustable roll gap spacing with micrometer calibration
- Roll shafts driven by geared motors and drive chains
- Automatic lubrication system for smooth running
- Touchscreen HMI control panel for easy operation
- Safety covers with interlocks for operator protection
Relevant Standards
- ISO 9001 – Quality management systems
- CE Marking – European safety standards
- ANSI B11 – Machine safety standards
- GB/T 13825 – Chinese national standard for roll forming machines
Major Manufacturers and Suppliers
| Company | Location |
|---|---|
| Bradbury Group | UK |
| Dimeco | USA |
| Metform | Turkey |
| ETM Rollforming | India |
| Howick Ltd | New Zealand |
| Botou Xianfa | China |
Price Range
| Capacity | Price Range |
|---|---|
| Small up to 800 mm width | $40,000 – $60,000 |
| Medium up to 1000 mm width | $60,000 – $80,000 |
| Large up to 1250 mm width | $80,000 – $120,000 |
| Heavy duty high speed | Above $120,000 |
Higher speeds, capacities, customization, and additional features increase costs.
Installation and Commissioning
- Install machine on flat, level concrete flooring
- Anchor machine securely to ground
- Supply strong power connection and earth wiring
- Install coil payoff reel and other uncoiling equipment
- Thread coil through roll former infeed guides
- Set roll gaps, test run profiles, adjust as needed
- Program control panel for required recipes
- Connect to exhaust fans, dust collection as needed
- Confirm electrical, pneumatic, lubrication systems functional
- Trial production runs and quality checks
- Formal handover and training by supplier
Operation and Maintenance
| Activity | Frequency |
|---|---|
| Coil loading | Per shift |
| Visual inspection | Per shift |
| Roll gap checking | Weekly |
| Roll and guide cleaning | Weekly |
| Lubrication top up | Monthly |
| Forming roll change | 6 – 12 months |
| Bearing inspection | Annually |
| Electrical testing | Annually |
| Machine calibration | Annually |
Proper operation and preventive maintenance enhances shutdowns. Keep suitable spare parts inventory.
Choosing a Shutter Door Roll Former Supplier
- Research options and shortlist suppliers
- Verify technical capabilities and experience
- Look for ISO certified manufacturers
- Consider customizable vs standard models
- Evaluate after sales service and local support
- Understand shipping costs and lead times
- Review production samples and visit reference plants
- Compare pricing of machines with similar specs
- Ensure confidence via calls with existing customers
- Optimize cost but don’t compromise on quality
Pros and Cons of Shutter Door Roll Forming Machines
Advantages
- Highly productive and efficient forming
- Consistent and quality profiles produced
- Reduces metal waste compared to other methods
- Low operational labor requirements
- Minimal supervision needed for automated lines
- Quick and easy profile and size changes
- Compact footprint compared to press brakes
- Lower cost than laser or waterjet cutting
- Safer enclosed forming method versus open fabrication
Limitations
- High initial capital investment
- Skilled personnel needed for setup and programming
- Rolls require periodic change depending on material
- Limited profile shapes compared to custom fabrication
- Not economical for low volume production
- Coil handling equipment also needed to unroll coils
Applications of Shutter Door Profiles
Roll formed shutter door profiles are used in a wide range of commercial and residential applications:
- Interior partition sliding doors
- Room dividers and adjustable partitions
- Window privacy screens and blinds
- Porch enclosures and balcony partitions
- Garage doors, shopfront shutters, and rolling doors
- Hurricane protection shutters
- Security shutters for doors and windows
- Cafe style foldable shutters
- Decorative wall paneling
- Solar shading exterior shutters
- Noise blocking and soundproofing shutters
- Insulated climate control shutters
Common places where shutter door profiles find usage:
- Houses, apartments, flats
- Offices, retail stores, malls
- Restaurants, cafes, hotels
- Warehouses, factories, workshops
- Commercial and public buildings
- Educational institutions like schools, colleges
- Healthcare facilities like hospitals, clinics
FAQ
What materials can be roll formed into shutters?
Most commonly galvanized steel and aluminum coils are used. Other metals like copper, brass can also be formed on smaller scales.
What thickness of metal sheet is recommended?
0.5 to 1 mm thickness is typical for shutters. Up to 1.2 mm sheets can be formed on heavy duty machines.
What is the production rate?
10 – 18 meters per minute. Varies based on metal thickness and product complexity.
How are different shutter profiles programmed?
Recipes are saved in the PLC for each profile shape. Operators select the desired recipe on the touchscreen.
What maintenance is required?
Roll cleaning, lubrication, visual checks daily. Roll changes, alignment, gearbox inspection every few months.
How long do the forming rolls last?
Approximately 12-18 months depending on hours run. Harder materials like stainless steel wear rolls faster.
What safety mechanisms are in place?
Guards with electromechanical interlocks, emergency stop buttons, two-hand operation, overload protection.
How is roll forming better for shutters than other methods?
Higher productivity, better consistency, lower cost, and less wastage versus fabrication methods.
What coil feeding accessories are needed?
Typically decoilers, straighteners, feed tables, levelers, joiners to run long production runs.
Can custom profiles be made?
Yes, new rolls can be engineered for custom profiles. Lead time and costs increase vs standard sections.
What parameters affect the pricing?
Speed, width, thickness range, automation features, and material impact costs. Premium for European or USA built machines.