Roll forming and manufacturer for roll forming technology
Technology for economical series
Roll forming is a continuous process for producing metal profiles with a consistent cross-sectional geometry. A strip material such as steel, stainless steel or aluminum is passed through several forming stations. The process is particularly suitable for medium to large quantities and impresses with its high dimensional accuracy, short cycle times and low tool costs compared to other forming techniques.
Profile technology with integrated processes - more than just forming
Integrated processing steps directly in the line
Process combinations for greater efficiency
Typical inline processes that are integrated into PoVoTec systems include pre- or post-punching with fixed or movable tools, laser or spot welding to produce closed profiles and automatic cutting to length using shears or saws. These combinations enable a significant reduction in production costs, as machine downtimes, workpiece handling and in-house transportation are reduced. In addition, the reproducibility of the parts is increased as all processing steps take place within the same clamping system.
Configurable production units
The integrated modules can be arranged variably depending on the component requirements – either before the roll forming process, between the forming stations or afterwards. This means that the line remains adaptable for different profile types without having to carry out fundamental conversions.
Materials and cross-sections - Roll forming in variants
Wide range of materials
Our roll forming lines are designed for different material requirements – from very thin strip to high-strength steel. The PS130 cassette processes material thicknesses between 0.07 and 1 mm, with a material width of up to 150 mm. With the reinforced version, up to 1.5 mm in steel is possible. Our PS400 cassette system is used for larger cross-sections. In the standard version, strips up to 2 mm thick with a width of 370 mm can be profiled. In the reinforced version, even up to 600 mm width and 4 mm material thickness can be realized – depending on requirements and design.
Technical capacities at a glance
The PS130 cassette has a center distance of 130 mm, while the PS400 system with a center distance of 400 mm is designed for larger and more resilient profile shapes. Depending on the cassette type, shaft diameters between 30 mm and 80 mm are used, adapted to the material and product requirements. The systems are designed for fast set-up processes and can be extended as required using modular plug-in connections.
Realizing individual profile shapes
Whether narrow guide rails, wide C-profiles or closed structures – PoVoTec develops the right solution for every profile type. Our roller set setup sheets enable precise, repeatable installation of the tools. As a result, the dimensional accuracy of your components remains constant – regardless of the material batch or batch size.
Roll forming: Manufacturer with in-house development, design and production
As a roll forming system manufacturer based in Eslohe, PoVoTec develops complete system solutions in-house – from the concept idea to delivery. Modern 3D CAD systems and PDM solutions are used in the design process. We manufacture the components for our machines ourselves on CNC-controlled milling and turning centers, which ensures consistent quality and short response times.
Roller sets and cassette technology from our own production
PoVoTec manufactures customized roller sets, special stations and modular assemblies such as our quick-change system, with which roll stands can be converted within a few minutes. This results in less downtime and the machines remain productive for longer. Even systems with up to 56 stations can be converted with just two crane movements.
Project support, modernization and after-sales
PoVoTec supports customers throughout the entire project period – from technical feasibility analysis, planning and production to commissioning on site. All departments – design, toolmaking, automation, electrical engineering and assembly – work seamlessly together.
Modernization of existing systems
In addition to new systems, we also offer retrofits of existing systems – including third-party systems. This includes the retrofitting of quick-change cassettes, the integration of new processing modules or the modernization of control technology. Older machines can also be made fit for new requirements.
Training, service and spare parts
After project completion, we continue to be available – with technical training, maintenance, spare parts service and remote maintenance solutions. Our aim is to keep your production line efficient and trouble-free in the long term. Close cooperation with the customer is an integral part of our self-image as a manufacturer.
Frequently asked questions about roll forming
How does roll forming differ from other forming processes?
In contrast to pressing or bending processes, roll forming is a continuous process. This allows higher quantities to be achieved with consistent quality and lower tool costs.
Can existing systems also be retrofitted?
Yes, PoVoTec also offers the retrofitting of quick-change systems, processing units and control technology for third-party systems. This makes your existing production future-proof.
What profile shapes are possible with roll forming?
Almost all open and closed cross-sections can be realized – from simple U and C profiles to complex hollow chamber structures with several functional areas.