Roll forming machines are essential in Russia’s metal processing and construction industries. These machines efficiently produce various metal profiles that are used in infrastructure, residential, and industrial applications. This article explores the most popular roll forming machines in Russia, covering types, specifications, profiles used, industries, main cities, and essential maintenance requirements. Additionally, we’ll discuss troubleshooting, benefits, and design standards, followed by how Machine Matcher can assist with purchasing and inspection.

Types and Specifications of Roll Forming Machines in Russia

Roofing Panel Roll Forming Machines
- Specifications:
  - Roller Materials: High-grade chromium steel (45# or GCr15)
  - Frame Structure: Heavy-duty steel frame, H-beam base
  - Drive System: Chain or gear drive with optional hydraulic system
  - Cutting System: Hydraulic cutting with post-cut or pre-cut options
  - Speed: 12-20 m/min (standard), high-speed options up to 40 m/min
- Profiles: Trapezoidal, corrugated, standing seam, and PBR panels
- Industries Using Them: Construction, residential, and commercial roofing sectors
- Main Cities: Moscow, Saint Petersburg, Novosibirsk, Kazan, and Yekaterinburg
C/Z Purlin Roll Forming Machines
- Specifications:
  - Roller Materials: High-strength alloy steel with heat treatment
  - Frame Structure: Welded steel frame with durable coating
  - PLC Control System: Automatic size adjustment and punching
  - Cutting Method: Hydraulic or servo cutting with punching and notching
  - Speed: 15-30 m/min
- Profiles: C, Z, and U purlins with multiple size adjustments
- Industries Using Them: Steel structure construction, warehouses, and industrial buildings
- Main Cities: Moscow, Samara, Nizhny Novgorod, and Rostov-on-Don
Highway Guardrail Roll Forming Machines
- Specifications:
  - Roller Materials: 45# steel with chrome plating
  - Frame Structure: Heavy-duty H-frame with high rigidity
  - Punching and Cutting: Hydraulic punching and guillotine cutting system
  - Speed: 8-15 m/min
- Profiles: W-beam, Thrie-beam, and crash barrier profiles
- Industries Using Them: Road safety, transportation, and infrastructure sectors
- Main Cities: Saint Petersburg, Moscow, Perm, and Chelyabinsk
Steel Deck Roll Forming Machines
- Specifications:
  - Roller Materials: Chromium-plated alloy steel
  - Frame Structure: High-strength steel with heat-treated rollers
  - Cutting System: Hydraulic shearing with programmable length control
  - Speed: 10-25 m/min
- Profiles: Ribbed deck panels, composite deck, and floor decking profiles
- Industries Using Them: High-rise construction, bridges, and industrial flooring
- Main Cities: Yekaterinburg, Moscow, Vladivostok, and Kazan
Gutter and Downspout Roll Forming Machines
- Specifications:
  - Roller Materials: Hardened steel with anti-corrosion coating
  - Drive System: Chain drive or gearbox with optional servo motor
  - Speed: 12-20 m/min
- Profiles: K-style, half-round gutters, and rectangular downspouts
- Industries Using Them: Residential and commercial drainage systems
- Main Cities: Moscow, Saint Petersburg, and Nizhny Novgorod

Typical Applications of These Machines

Roofing Systems: Panels and profiles for residential and commercial roofing
Structural Support: Purlins and decks used in industrial buildings and warehouses
Road Safety Infrastructure: Guardrails for highways and public roads
Drainage Systems: Gutters and downspouts for water management
Flooring Systems: Metal decking for bridges and high-rise buildings

Main Manufacturers of Roll Forming Machines in Russia

Stankostroitel Moscow LLC: A leading manufacturer producing high-performance roll forming lines.
MetProm Engineering: Specializing in roofing panel and guardrail forming machines.
TechMash Rollforming Systems: Known for their custom solutions for C/Z purlin and steel deck roll forming.
VladSteel Machinery: Providing complete roll forming lines for industrial and structural applications.

Set Up and Operation of Roll Forming Machines

Uncoiling: Load the coil onto the uncoiler, ensuring proper alignment.
Feeding and Guiding: Feed the sheet into the machine through guide rollers.
Roll Forming Process: The metal strip passes through successive roller stations to achieve the desired profile.
Cutting and Punching: Hydraulic or servo cutting system trims profiles to the required lengths.
Stacking and Collection: Finished profiles are stacked automatically or manually.

Maintenance of Roll Forming Machines

Daily Maintenance:
- Lubricate the rollers and bearings.
- Check the alignment of rollers and guide rails.
Weekly Maintenance:
- Inspect the hydraulic system for leaks or pressure loss.
- Clean the machine thoroughly to remove metal debris.
Monthly Maintenance:
- Calibrate the PLC system and check electrical connections.
- Check and replace worn-out rollers and cutting blades.

Troubleshooting Common Issues

Misaligned Profiles: Realign the guide rollers and check the material feeding system.
Inconsistent Cutting Lengths: Recalibrate the PLC and check hydraulic pressure.
Excessive Roller Wear: Inspect and replace damaged or worn-out rollers.
Hydraulic Malfunction: Check the oil levels and hydraulic valve connections.

Limitations of Roll Forming Machines

Profile Flexibility: Limited to predefined profiles unless customized.
Material Thickness: Variations in thickness may affect profile consistency.
High Initial Investment: Machines require a significant upfront cost.

Benefits of Roll Forming Machines

High Efficiency: Continuous forming process increases production speed.
Precision and Consistency: Produces uniform profiles with minimal waste.
Reduced Labor Costs: Automated systems reduce manual intervention.
Scalability: Machines can produce different profiles with minor adjustments.

Installation and Commissioning

Site Preparation: Ensure a leveled surface with adequate space for the machine and coil feeding area.
Machine Assembly: Assemble the rollers, frame, and cutting units.
Electrical Connection: Connect to the power supply with correct voltage specifications.
Initial Calibration: Run trial materials to calibrate speed, roller pressure, and cutting accuracy.
Operator Training: Provide basic operational training to the machine operators.

Operation and Maintenance Guidelines

Operator Safety: Ensure all safety guards and enclosures are in place.
Daily Start-up Checks: Verify roller alignment and oil levels before starting.
Shutdown Procedure: Follow a systematic shutdown process to avoid damage to the system.

Design Standards for Roll Forming Machines

ISO 9001: Ensuring quality management systems in manufacturing.
CE Certification: Compliance with European safety and quality standards.
GOST Certification: Russian standard compliance for machine performance and safety.

How Machine Matcher Can Help with Buying and Inspection

Machine Matcher is your trusted partner in sourcing the best roll forming machines in Russia. Our expertise ensures that you get the most suitable machine for your profile requirements. We offer:

Comprehensive Inspection: Thorough machine inspections to verify specifications, quality, and operational efficiency.
Expert Consultation: Our team of experts analyzes your production needs and recommends the right machine.
Customization Options: Assistance with modifying machines to meet unique profile or material requirements.
Seamless Buying Process: We handle negotiations, shipping, and customs clearance to ensure smooth delivery.
After-Sales Support: Ongoing technical assistance and spare part availability to keep your machine running efficiently.