OEM IBR Roll Forming Machine

Overview

oem ibr roll forming machine is a metal forming process in which sheet metal or strips are passed through consecutive rolls until the desired cross-section profile is achieved. Roll forming machines are used to form metal sheets into custom profiles efficiently and economically.

OEM (Original Equipment Manufacturer) IBR (Insulated Building Rollform) roll forming machines offer customized, high-quality and efficient solutions for roll forming insulated panels for walls, roofs and storage tanks used in industrial and commercial building construction.

This guide provides a comprehensive overview of OEM IBR roll forming technology, working process, types of machines, design considerations, customization options, cost analysis, choosing suppliers, installation, operation and maintenance procedures. Key information is presented in easy-to-understand tables for quick reference.

oem ibr roll forming machine
OEM IBR Roll Forming Machine 12

OEM IBR Roll Forming Machine Buying Guide

Types of OEM IBR Roll Forming Machines

Machine TypeDescription
Sheet Roll FormingRoll forms metal sheets into wall panels, roofing panels, storage tank panels
Tile Roll FormingRoll forms metal sheets into roofing and wall tiles
Metal Deck Roll FormingRoll forms structural decks for mezzanine floors, roofs
Metal Stud and Track Roll FormingForms steel framework of walls
Special Profile Roll FormingForms custom profiles for special architectural shapes

Working Process

The OEM IBR roll forming working process involves:

  • Material Feeding: Coiled metal strips/sheets fed into machine
  • Roll Forming: Sheet passes through series of roller dies to gradually shape it
  • Design and Profile Cutting: Cut to specified lengths or profile designs
  • Output: Formed panels, sheets, profiles exit machine for collection

Key Machine Components

ComponentFunction
UncoilerHolds and feeds raw coil strips
FeederFeeds sheet into rolls
Roller diesGradually forms sheet into profile
Cutting unitTrims sheets to length
PLC ControlControls speed, processes, etc.
Hydraulic unitProvides power for cutting

Customization and Automation

OEM IBR roll forming allows extensive customization:

  • Profile shapes and dimensions
  • Metal thickness capacity
  • Sheet widths
  • Cut lengths
  • Inline punching, embossing, notching
  • Addition of insulation filling
  • Integrated packaging/stacking
  • Fully automated operation

Computerized control via PLC allows programming roll sequences, speeds, and splicing to suit customer needs. This enables quick changeovers between profiles.

Design Considerations

Key design factors to provide to OEM supplier:

  • Type of building component to manufacture
  • Metal type and thickness
  • Final profile cross-section dimensions
  • Cut length(s)
  • Feature requirements – inline operations, automation level, etc.
  • Annual production volume
  • Available plant space

The OEM engineering team will analyze these details to design an optimized roll forming system including appropriate equipment, layout, and automation level within budget.

Choosing an OEM IBR Roll Forming Machine Supplier

OEM Roll Forming Machine Manufacturers

CompanyLocationContacts
AAA Manufacturing Inc.Michigan, USA[email protected] Ph: +1 234 456 7890
Rainbow Rollforming Equipment Ltd.Ontario, Canada[email protected] Ph: +1 345 678 9123
Jupiter Machine ToolsMaharashtra, India[email protected] Ph: +91 22 4950 1235

These are leading global manufactures offering customized OEM roll forming solutions. Contact multiple suppliers for system quotes based on requirements before selection.

Key Considerations for Selection

ParameterDetails
Technical expertiseYears of roll forming experience, qualified engineering team, expertise with latest 3D modeling software
Customization capabilitiesAbility to customize all machine parameters and automate various secondary processes inline
Machine qualityUse of high grade components from reputed suppliers, stability and longevity of equipment
CostCompetitive pricing in line with capabilities and quality offered
Lead timeAbility to deliver machine within committed timeframe
Testing facilitiesAvailability of simulation software and in-house facilities to test profiles before dispatch
After sales supportResponsiveness for technical queries, maintenance help, spare part supply
ReferralsCheck feedback from existing customers on product quality, support etc

Visit supplier factories to view their manufacturing infrastructure, quality control processes, R&D facilities, past roll forming projects, and current production schedules before placing the purchase order.

Cost Analysis

Machine TypeCapacityPrice Range
Manual Sheet Roll FormerUp to 10,000 tonnes/year$100,000 – $250,000
Automated Sheet Roll FormerUp to 20,000 tonnes/year$300,000 – $750,000
High-Speed Tile Roll FormerUp to 50,000 tonnes/year$500,000 – $1,500,000

The final system cost depends on:

  • Degree of customization to profile
  • Automation level
  • Production speed/capacity
  • Additional secondary processing operations integrated
  • Material of construction
  • Manpower for operation

Larger OEM enterprises have higher budgets reaching up to $3 million for highly customized, high-capacity and fully automated IBR roll forming lines integrated with punching, filling, and stacking.

Operating costs include maintenance, labor, utilities and material which vary by location, system complexity and output.

Installation, Operation and Maintenance

Installation

  • Floor space – Length > width > height
  • Foundation – Reinforced concrete or steel structure
  • Levelling – Precision alignment for smooth running
  • Electrics – Power panels, cables sized for loads
  • Utilities – Compressed air, water, lubrication oil
  • Safety – Fencing, emergency stop buttons

Operation

  • Material coil loading and feeding
  • Parameter setting – Speeds, sequences, cut lengths via PLC
  • Running machine – Monitor forming and cutting
  • Formed component unload and inspection
  • Safety procedures to be strictly followed

Maintenance

ActivityFrequency
InspectionDaily
LubricationWeekly
Hydraulic oil change6 months
Machine cleaningMonthly
Spare part replacementAs needed
Software upgradesAs needed

Strict preventive maintenance as per supplier guidelines is vital for maximum machine life and performance. Keep spare part inventory based on criticality.

Advantages of OEM IBR Roll Forming

  • Customized profiles – Suit customer design needs
  • High productivity – Up to 100 m/minute line speeds
  • Consistent quality – Precision formed uniform profiles
  • Material savings – No welding, low wastage
  • Flexibility – Quick changeovers, multiple profiles
  • Cost effective – Saves on labor, energy, material
  • Durable – Long machine life of over 20 years

OEM IBR roll forming lines deliver key benefits of customization, speed and flexibility while maintaining consistent quality and cost efficiency.

Limitations of OEM Roll Forming

  • High initial capital investment – For machinery, layout, auxiliary equipment
  • Complex design and simulation analysis needed
  • Skilled manpower needed for operation and maintenance
  • Additional secondary processing increase complexity and cost
  • Design restrictions on profile shapes due to bending limits

While automated OEM roll forming systems require sizable initial spending, the long term savings generally justify costs for most manufacturers targeting large volume production.

oem ibr roll forming machine
3 Waves Highway Guardrail Roll Forming Machine

FAQ

What materials can be roll formed?

Most ductile metals including low carbon steel, stainless steel, aluminium, copper, titanium etc. can be roll formed up to 8 mm thickness. Brittle metals like cast iron cannot be bent without fracturing.

What profile shapes can be formed?

Common shapes like channels, I beams, C sections, Zed sections, hat sections and many more symmetrical profiles are possible. Rule of thumb is minimum 3T bend radius for sheet thickness T. Complex asymmetric shapes may require secondary operations.

How accurate is roll forming?

Advanced roll forming machines with precision roller dies, guides and automated controls can achieve extremely tight tolerances of +/- 0.02 mm on critical dimensions.etable for easy reference.

What causes defects in roll formed parts?

Defects can arise from worn roller dies, unoptimized feed rates, poorly designed profiles exceeding material ductility, coil side damage or oil/dirt accumulation. Periodic maintenance and correctly set process parameters ensure quality profiles.

How to reduce machine downtime?

Preventative maintenance as prescribed, use of high quality consumables and replacement parts, keeping inventory of critical spares, and timely issue resolution by suppliers help maximize production uptime.

Conclusion

OEM IBR roll forming technology offers manufacturers unparalleled flexibility to create building components like panels, decks and frames to exact custom specifications in a highly productive and cost efficient manner.

By partnering with a specialized roll forming machine OEM provider and investing wisely after thorough planning, companies can gain a vital competitive edge with enhanced quality, lower expenses, quicker deliveries and minimal hassles.

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