Glazed Roof Tile Roll Forming Machine

glazed roof tile roll forming machine is an important equipment used for manufacturing interlocking roofing tiles with a protective glazed coating. This guide provides a comprehensive overview of glazed roof tile roll forming machines covering their working, types, applications, specifications, selection factors, installation, operation, maintenance and more.

Overview of Glazed Roof Tile Roll Forming Machine

A glazed roof tile roll forming machine is designed to transform metal coils into formed interlocking roofing tiles which are then coated with a glazed finish.

What are Glazed Roof Tiles?

Glazed roof tiles are interlocking roof covering tiles with a ceramic glazed coat finish. The glaze provides a protective, waterproof and decorative finish on the formed metal roof tile.

Working Principle of Glazed Roof Tile Roll Forming Machine

A glazed roof tile roll forming machine takes metal coil as input and converts it into formed roofing tiles by passing through consecutive roll forming stations. The profiles tiles are then spray coated with glaze before cut-off and stacking.

Key processes:

  • Coil sheet feeding
  • Progressive roll forming into roof tile profile
  • Application of glaze coat on tiles
  • Cutting individual tiles as per length
  • Stacking of finished tiles

Advanced machines allow quick changeover to different tile sizes and profiles.

Types of Glazed Roof Tile Roll Forming Machines

Glazed roof tile roll forming machines are available in different configurations:

Based on Automation

  • Manual
  • Semi-automatic
  • Fully-automatic PLC controlled

Based on Production Speed

  • Low speed: Up to 10 m/min
  • Medium speed: 10 – 30 m/min
  • High speed: Above 30 m/min

Based on Tile Types

  • Interlocking flat tile profile
  • Interlocking roman tile profile
  • Custom tile profiles

Based on Glazing Method

  • Manual spray glazing
  • Automatic roller/curtain glazing
  • Fluorocarbon glaze coatings for durability

Based on Processing

  • Roll forming only
  • Roll forming + glazing line
  • Roll forming to palletizing integrated system
glazed roof tile roll forming machine
Glazed Roof Tile Roll Forming Machine 3

Applications of Glazed Roof Tiles Produced by Roll Forming

Glazed roof tiles made by roll forming find application in:

  • Residential roofing for houses, villas, apartments
  • Commercial buildings like offices, shops, lodges etc.
  • Warehouses, barns, garages roof covering
  • Re-roofing and replacement of old roofing tiles
  • Temporary structures and exhibition shed roofing
  • Decorative roofing accents and housing elements
  • Roof rainwater drainage and guttering elements

Glazed tiles offer durability, decorative finish and waterproofing for roofing needs.

Glazed Roof Tile Roll Forming Machine Specifications

Glazed roof tile roll forming machines are available with different specifications based on output and production needs:

SpecificationsTypical Range
Production Speed10 – 50 m/min
Tile Width300 – 1000 mm
Tile Thickness0.35 – 1 mm
কয়েল প্রস্থUp to 1250 mm
Coil Thickness0.30 – 0.8 mm
Forming Stations16 – 24
Power Consumption15 – 40 kW
Voltage380V, 50Hz, 3 Phase
Machine Weight8000 – 15000 kg
Machine Size10 – 25 m Long x 3 – 4 m Wide

These parameters can be customized as per specific production requirements.

Design and Working Standards

Glazed roof tile roll forming machines need to adhere to certain design standards:

  • Robust steel frame construction with precision leveled forming beds
  • Hardened roll tooling for extended service life
  • Multi-axis powered decoiler for smooth feeding
  • Independent AC drive motors for controlled forming
  • Automatic edge milling and punching stations
  • Hydraulic system for tile pressing and punching
  • Adjustable forming stations for quick size changeovers
  • Safety guarding for operator protection

Suitable framing arrangements should be provided for glazing application modules.

Choosing a Glazed Roof Tile Roll Forming Machine Manufacturer

Here are some tips for choosing a good glazed roof tile roll forming machine manufacturer:

পরামিতিWhat to Look For
অভিজ্ঞতাNumber of years in business, proven track record
উৎপাদনIn-house manufacturing with quality control
কাস্টমাইজেশনAbility to customize machine to needs
QualityAdvanced automation for consistent quality
CertificationISO 9001, CE certifications
Service SupportInstallation, commissioning and operator training
CostCompetitive pricing and payment terms
InventoryReady models available for faster delivery
LocationDistance for logistics and service support
  • Check sample tiles from machine for quality assurance
  • Ensure availability of spares, service support
  • Compare cost, production rate and delivery time
  • Inspect machine manufacturing facility if possible
  • Choose a reputable manufacturer for reliability

This helps get high performance glazed roof tile roll forming machines as required.

Installation of Glazed Roof Tile Roll Forming Machine

Proper installation is important for smooth functioning of a glazed roof tile roll forming line:

  • Prepare level concrete foundation as per layout drawings
  • Position the machine components using cranes/forklifts
  • Assemble the roll forming sections, decoiler, pressure unit as per drawings
  • Install the tile pressing, punching and embossing stations
  • Connect the electrical motors, controls, hydraulics per manual
  • Wire up the electrical switches, drives and sensors
  • Install safety guarding around the moving components
  • Check lubrication levels on all gear systems
  • Test run the machine and make adjustments as required

Correct installation as recommended by the manufacturer is critical.

Working and Operation of Glazed Roof Tile Roll Forming Machine

Working a glazed roof tile roll forming machine involves these key steps:

Pre-Operation Checks and Settings

  • Check electrical wiring, hydraulics, lubrication
  • Set up decoiler brake tension as per tile gauge
  • Adjust rollers in each station for proper material flow
  • Set cutting length based on tile size
  • Adjust glazing spray nozzles as per tile width
  • Test glaze pump, valves, spray headers for readiness
  • Clear any material scrap or residues in the line

Starting the Machine

  • Turn on the machine drives in jog mode
  • Start the decoiler to feed the metal coil through stations
  • Gradually increase production speed to set levels
  • Initiate glazing spray system and set paint pressure
  • Adjust trim knives for edge cutting if needed
  • Check tile quality and optimize forming gradually
  • Initiate auto stacker once line is stabilized

During Operation

  • Monitor line for any jams, noise issues and stop if arising
  • Conduct periodic quality checks on tile dimensions
  • Ensure proper lubrication on all moving components
  • Monitor the coil diameter and plan decoiler coil change
  • Inspect glazing nozzle spray pattern and coverage
  • Touch up tile surface finish if required
  • Clear any accumulated scrap or tiles from the line

Shut Down

  • Stop the decoiler and allow material to clear the line
  • Switch off the glazing pumps and blow out the lines
  • Gradually reduce speed to zero and shut off drives
  • Clean the machine thoroughly before next use

Following recommended procedures is key for optimal functioning.

Maintenance of Glazed Roof Tile Roll Forming Machines

Regular preventive maintenance activities ensure continuous working of the glazed roof tile roll forming line:

ActivityFrequencyMethod
CleaningDailyRemove tile and glaze buildup, dust, scrap
InspectionDailyCheck for leaks, abnormal noise
LubricationWeeklyGrease bearings, gears, apply chain lube
Roller InspectionMonthlyCheck contour wear, replace if needed
Drive InspectionMonthlyCheck chains/belts tension, adjust/replace
HydraulicsQuarterlyCheck cylinders, pipes for leakages
ElectricsHalf-yearlyCheck loose connections, insulations
CalibrationYearlyCalibrate pressure sensors, controllers
  • Maintain daily, weekly and monthly preventive schedules
  • Schedule longer maintenance during shutdowns
  • Keep sufficient spares like rollers, seals, belts in stock
  • Train technicians on equipment maintenance procedures
  • Track machine hours run and maintenance logs

Proper maintenance improves equipment life and avoids downtime.

Troubleshooting Common Issues in Glazed Roof Tile Roll Forming Machines

Some common issues faced in glazed roof tile roll forming machines are:

IssuePossible CausesSolutions
Coil jammingImproper decoiler brake setup
Worn rollers
Edge damage
Adjust decoiler brake
Replace worn forming rollers 
Use edge trimmed coils
Tile distortionImproper roller gaps
Station misalignment
Reset roller gaps
Realign forming section levels
Glaze drippingImproper spray pressure
Nozzle clogged
Adjust glaze pump pressure
Clean nozzles
Machine vibrationLoose foundation bolts
Misaligned gearbox
Tighten foundation bolts
Realign gearbox and shafts
Hydraulic oil leakSeal damage
Hose breach
Identify and replace damaged seal
Replace breached hose

Analyzing root causes and fixing deficiencies can resolve common machine issues.

Improving Productivity of Glazed Roof Tile Roll Forming Machines

Some ways to improve productivity from glazed roof tile roll forming machines are:

  • Optimize line speed by reducing bottlenecks
  • Schedule quick size changeovers to maximize production runs
  • Automate downstream processes like stacking and packaging
  • Ensure consistent quality of input metal coils
  • Train operators on standard operating procedures
  • Perform regular preventive maintenance to minimize downtime
  • Use IoT sensors for remote monitoring and diagnostics
  • Analyze downtime reasons and address weak spots
  • Keep sufficient spares inventory to reduce downtime
  • Upgrade machine with latest automated features

The right initiatives can significantly improve the productivity of glazed roof tile roll forming lines.

glazed roof tile roll forming machine
Glazed Roof Tile Roll Forming Machine 4

FAQs

Q: What is the production capacity of these machines?

A: Production capacity depends on speed and profiles – typically around 400-800 tiles/hr for medium speed machines.

Q: What are the regular maintenance activities required?

A: Maintenance involves cleaning, lubrication, inspection & replacement of rollers, seals, belts, chains as per schedule.

Q: What is the typical accuracy achieved on these machines?

A: Advanced machines with servo control can achieve dimensional accuracy up to ±0.5 mm and angular accuracy up to ±1°.

Q: What consumables are required during operation?

A: Metal coils, glaze paint, lubricants, hydraulic oil, spare parts like belts, seals are required.

Q: What is the typical lifespan of these machines?

A: Around 15-20 years lifespan can be achieved with proper maintenance.

Q: What factors affect the pricing of these machines?

A: Speed, automation level, tile size range, and optional accessories impact the overall cost.

Q: What is the typical power consumption?

A: Power consumption is typically 15-40 kW depending on the machine size and configuration.

Q: What installation support is provided?

A: Manufacturers provide installation guidelines, drawings, technicians support and operator training.

Q: What is the typical delivery time?

A: Ready standard models take 1-2 months while customized machines take 3-4 months delivery time.

উপসংহার

The glazed roof tile roll forming machine is an efficient equipment enabling automated production of interlocking roofing tiles with protective glazing in various sizes. This guide has provided a comprehensive overview of all relevant aspects of glazed roof tile roll forming machine selection, installation, operation and maintenance to maximize productivity and product quality.

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