Most Popular Roll Forming Machines in Japan

Japan, known for its cutting-edge technology and high manufacturing standards, has a thriving market for roll forming machines. These machines are widely used across various industries, including construction, automotive, and energy. This guide explores the most popular roll forming machines in Japan, highlighting their specifications, profiles, applications, maintenance requirements, and operational guidelines. We will also discuss the pricing range, leading manufacturers, troubleshooting, benefits, and limitations. Finally, we’ll explain how Machine Matcher can assist in purchasing the ideal roll forming machine suited to your business needs.

Popular Types of Roll Forming Machines in Japan

1. Roofing Panel Roll Forming Machines

• Specifications:

  • Roller Materials: High-grade steel with chrome coating

  • Frame Size: 300–450 mm

  • Motors: 5–15 kW, depending on production speed

  • PLC System: Mitsubishi, Panasonic, or Siemens-based

  • Cutting: Hydraulic cutting with precision blade system

  • Machine Speed: 12–30 m/min

• Profiles Produced: Trapezoidal panels, corrugated panels, standing seam, and metal roofing sheets

• Industries: Construction, residential and commercial building projects

• Main Areas of Use in Japan: Tokyo, Osaka, Yokohama, and Nagoya

2. Highway Guardrail Roll Forming Machines

• Specifications:

  • Roller Materials: Hardened steel with anti-corrosion coating

  • Frame Size: 350–500 mm

  • Motors: 18–30 kW for high production speed

  • PLC System: Fully automated with advanced HMI interface

  • Punching and Cutting: Hydraulic punching and cutting

  • Machine Speed: 10–25 m/min

• Profiles Produced: W-beam and thrie-beam guardrails

• Industries: Infrastructure, road safety, and highway projects

• Main Areas of Use in Japan: Hokkaido, Fukuoka, Sapporo, and Kyoto

3. Purlin Roll Forming Machines (C and Z Profiles)

• Specifications:

  • Roller Materials: Hardened alloy steel with zinc coating

  • Frame Size: 300–450 mm

  • Motors: 15–25 kW for high production rates

  • PLC System: Advanced control with touch screen interface

  • Cutting System: Servo-controlled hydraulic cutting

  • Machine Speed: 12–25 m/min

• Profiles Produced: C and Z purlins

• Industries: Steel structure construction, industrial building projects

• Main Areas of Use in Japan: Osaka, Kobe, Hiroshima, and Kawasaki

4. Deck Roll Forming Machines

• Specifications:

  • Roller Materials: Heat-treated steel with chrome finish

  • Frame Size: 350–500 mm

  • Motors: 18–30 kW, high-efficiency motors

  • PLC System: Siemens or Mitsubishi system with real-time monitoring

  • Punching and Cutting: Hydraulic notching and cutting

  • Machine Speed: 12–20 m/min

• Profiles Produced: Floor deck panels

• Industries: Commercial and industrial buildings, multi-story construction

• Main Areas of Use in Japan: Tokyo, Osaka, Yokohama, and Saitama

5. Solar Mounting Bracket Roll Forming Machines

• Specifications:

  • Roller Materials: High-strength steel with anti-rust coating

  • Frame Size: 300–450 mm

  • Motors: 10–20 kW

  • PLC System: Fully automated with real-time diagnostics

  • Cutting: Hydraulic cutting for precise edges

  • Machine Speed: 15–25 m/min

• Profiles Produced: Solar mounting brackets and support structures

• Industries: Renewable energy sector

• Main Areas of Use in Japan: Fukushima, Tokyo, Kyoto, and Nagasaki

Machine Setup and Operation

Machine Setup

• Unpack and inspect all machine components.

• Position the machine on a flat, stable surface.

• Connect the power supply as per the manufacturer’s guidelines.

• Load the coil properly using a coil car or uncoiler.

• Adjust the roller dies according to the desired profile.

Operation Process

1. Input Material: Feed the coil into the machine.

2. Profile Calibration: Adjust the rollers for precision.

3. Forming and Cutting: The profile takes shape as it passes through the rollers and is cut to length.

4. Stacking and Packaging: Finished profiles are stacked and prepared for shipment.

Maintenance Requirements

• Daily: Check for loose bolts and lubricate moving parts.

• Weekly: Inspect roller dies and check for wear and tear.

• Monthly: Clean hydraulic systems and inspect PLC connections.

• Annually: Conduct a full system diagnostics and recalibrate the machine.

Troubleshooting Common Issues

1. Misalignment of Profiles: Realign rollers and adjust tension settings.

2. Uneven Cutting: Inspect and sharpen the cutting blades.

3. Hydraulic Leaks: Tighten hydraulic seals and inspect for damage.

4. PLC Malfunction: Check power supply and software configurations.

5. Material Jamming: Clear any obstructions and ensure smooth coil feeding.

Limitations of Roll Forming Machines

• High Initial Investment: Roll forming machines can be expensive.

• Profile Limitation: Machines are generally designed for specific profiles.

• Space Requirements: Large footprint requires significant floor space.

• Operator Training: Skilled operators are needed for smooth operation.

Benefits of Roll Forming Machines

• High Production Speed: Consistent and efficient production.

• Low Waste Generation: Minimal material wastage.

• Profile Versatility: Can produce complex profiles with precision.

• Long Service Life: Durable construction ensures extended machine lifespan.

Typical Applications of Roll Forming Machines

• Construction Industry: Roofing panels, floor decks, and structural components.

• Automotive Sector: Structural reinforcements and interior paneling.

• Renewable Energy: Solar mounting structures.

• Infrastructure Projects: Guardrails and safety barriers.

International Price Range for Roll Forming Machines

• Roofing Panel Roll Forming Machines: $25,000–$120,000

• Highway Guardrail Roll Forming Machines: $60,000–$180,000

• Purlin Roll Forming Machines: $35,000–$150,000

• Deck Roll Forming Machines: $50,000–$200,000

• Solar Mounting Bracket Roll Forming Machines: $40,000–$150,000

Leading Roll Forming Machine Manufacturers in Japan

• Yamato Machinery Co., Ltd.

• Sankyo Seiki Co., Ltd.

• Hitachi Zosen Corporation

• Fujita Works Ltd.

• Kobe Steel Ltd.

Installation and Commissioning

1. Site Preparation: Ensure a clean and level workspace.

2. Machine Positioning: Place the machine in the correct position for efficient operation.

3. Electrical Connection: Connect to the required power supply.

4. Testing and Calibration: Run initial tests and calibrate the rollers.

5. Operator Training: Provide hands-on training to operators.

Why Machine Matcher is the Best Choice for Buying Roll Forming Machines

Machine Matcher specializes in helping buyers find the best roll forming machines that meet their specific profile needs. With a large inventory and expertise in the roll forming industry, Machine Matcher ensures:

• Comprehensive Machine Inspections: Ensuring machine quality before purchase.

• Customized Solutions: Matching machines to your exact profile requirements.

• Global Network of Manufacturers: Access to top manufacturers across Japan and beyond.

• Expert Guidance: Our team helps with setup, installation, and operational guidance.

Design Standards for Roll Forming Machines in Japan

• JIS (Japanese Industrial Standards): Ensures machine quality and safety.

• ISO Certification: Compliance with international quality standards.

• CE Marking: For exports, machines comply with European safety standards.

Contact Machine Matcher

Speak to one of our roll forming machine experts today:

• UK: +44 20 335 56554

• USA: +1 407 559 7948

• Europe: +32 460 24 13 95

• WhatsApp: +44 20 335 56554

• Email: [email protected]