Automatic line for drywall profiles

ROLLFEN MAKİNA CD60 UD28 CW 50-75-100 UW 50-75-100

1. PRODUCT RANGE (PROFILE TYPES)
The line is equipped with tools and rollers for producing all standard wall and ceiling profiles:
• Wall profiles: CW50, CW75, CW100 and UW50, UW75, UW100
• Ceiling profiles: CD60 and UD28
2. TECHNICAL SPECIFICATIONS AND PERFORMANCE
Production unit (Rollforming Line):
• Production speed: * Up to 60 meters/minute (without punching)
o Up to 30 meters/minute (with the production of two holes in the profile)
• Input material and thickness: Galvanized sheet DX51D+Z (thickness from 0.50 mm to 0.70 mm)
• Coil width: Maximum 205 mm
• Power consumption and connection: Total power 14 kW (actual consumption approx. 7 kWh), power cable 5x10
• Compressed air requirement: 8 Bar (consumption during operation only 2 l/min, unit capacity 100 l/min)
• Layout of the production unit: 15 m (length) x 3 m (width) x 3 m (height)
Automatic packing and palletizing unit (Profile Packing System):
• Packing speed: 2.5 packs / minute
• Length of finished profiles from 2000 mm to 6000 mm
• Power consumption of the packing system: Total power 30 kW (actual consumption approx. 12 kWh), 3-phase connection 380 V
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• Compressed air for packing: 8 Bar (consumption 7 l/min)
3. DETAILED OVERVIEW OF LINE COMPONENTS
1. Uncoiler
• Maximum coil width: 205 mm, outer coil diameter up to 1200 mm
• Load capacity: up to 2500 kg
• Non-motorized system with integrated safety wire mesh fence.
2. Rollforming Machine
• Conventional type with roller change (14–15 forming stations)
• Shaft diameter: 40 mm | Maximum width between stands: 197 mm
• Roller shafts made of hardened and ground steel, supported at both ends. Upper shafts are adjustable according to sheet thickness with a precise Vernier scale.
• Rollers made of high-quality alloy steel S 4140, precision machined and heat-treated to a hardness of 55–57 HRC for extremely long service life.
3. Flying Shear Cutting & Punching Unit
• Flying shear, mounted on slides and guide rails for translational movement, driven by a servo motor and gearbox.
• Knives/blades made of alloy steel for cold working, hardened to 60–62 HRC (exceptionally clean and precise cutting without deformation).
• Protected by a safety fence.
4. Automatic Stacking, Strapping and Palletizing System (GHT-SIC-V3)
• Automatic profile joining: Connecting system with straps transfers profiles to a group for stacking. Note: Smaller profiles (e.g., UD28), which are not suitable for machine stacking, are simply placed manually on the operator table.
• Automatic strapping machine: High-speed brushless motors, speed up to 65 straps per minute, electronic control of tension force (1–35 kg) and control of strap welding temperature (widths 5, 6 or 9 mm).
• Automatic electronic palletizer with forks (Mod. 50kg): Fully electronically controlled movement system along all axes via electro-braking drive with inverters (frequency converters), which ensures extremely smooth acceleration/deceleration and gentle handling of packages to prevent material damage.
5. Advanced CNC/PLC control system
• Built-in components from recognized global brands.
• Industry 4.0 (IND 4.0 PLC) controller with simple input of parameters (product lengths, quantities) via a central terminal.
• Stepless (infinite) regulation of production speed and perfect synchronization of all machines in the line.
• Built-in safety modules (Emergency stop).

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