Roll forming is a key manufacturing process in the United States, used in industries ranging from construction and automotive to solar and infrastructure. With American companies pushing for precision, productivity, and durability, roll forming machines have become a staple in many factories. This guide covers the most popular roll forming machines in the U.S., including specifications, profiles, industry applications, setup and operation, maintenance, and price ranges.

1. Roofing Panel Roll Forming Machines

Common Profiles: PBR panels, R panels, AG panels, standing seam, corrugated panels
Industries: Residential, commercial, and industrial roofing and cladding
Machine Specs:

• Roller material: GCr15 steel with hard chrome coating
• Frame: 350H steel structure, welded and stress-relieved
• Motor: 7.5–15 kW depending on model
• Cutting: Hydraulic post-cut with Cr12 blades
• PLC: Siemens or Mitsubishi touch screen control
• Speed: 15–45 m/min

Maintenance:

• Weekly lubrication of moving parts
• Periodic roller alignment checks
• Cleaning of hydraulic system filters every 3 months

2. Drywall Roll Forming Machines (Stud & Track)

Common Profiles: U-track, C-stud, furring channel
Industries: Interior construction, drywall framing, prefabricated buildings
Machine Specs:

• Roller material: Cr12MoV with heat treatment
• Motor: 5.5–11 kW
• Frame: 300H welded steel
• Cutting: Servo-follow cut with automatic length detection
• PLC: Delta or Siemens
• Speed: Up to 40–60 m/min

Maintenance:

• Clean dust and debris daily
• Grease the chain drive weekly
• Inspect servo motor belts monthly

3. Highway Guardrail Roll Forming Machines

Common Profiles: W-beam and thrie-beam guardrails
Industries: Highway infrastructure, traffic safety
Machine Specs:

• Rollers: Forged steel with precision machining
• Frame: 500H high-rigidity welded frame
• Motors: Up to 30 kW
• Punching: Hydraulic punching with servo feeding
• Cutting: Hydraulic shearing with pre-cut and post-cut options
• PLC: Siemens with remote access option

Maintenance:

• Hydraulic oil replacement every 6 months
• Calibration of punching station quarterly
• Annual inspection of the drive system

4. Door Frame and Garage Door Roll Forming Machines

Common Profiles: Jamb, head, sill frames; roll-up door slats
Industries: Residential and industrial door manufacturers
Machine Specs:

• Rollers: GCr15 hardened and precision-ground
• Motor: 11–18.5 kW
• Cutting: Pneumatic or hydraulic cutting
• Frame: 400H steel with robust side panels
• Optional: Embossing station, notching unit

Maintenance:

• Regular lubrication of notching unit
• Clean embossing rollers weekly
• Inspect hydraulic cylinders every 2 months

5. Solar Mounting Bracket Roll Forming Machines

Common Profiles: C, Z, Sigma channels, strut channels
Industries: Solar energy, renewable installations, utility infrastructure
Machine Specs:

• Rollers: Cr12MoV with black oxidation treatment
• Frame: Modular steel platform
• Motor: 15 kW with inverter
• Punching: CNC inline punching system
• Speed: 20–30 m/min
• PLC: Omron or Siemens

Maintenance:

• Weekly inspection of inline punching heads
• Coolant fluid level checks
• Quarterly electrical system check

Machine Setup and Operation

1. Installation: Requires a flat, vibration-free foundation with proper anchoring. Electrical connections must match machine power requirements (typically 220V or 440V in the U.S.).
2. Coil Loading: Place coil on uncoiler, thread material through feeder into the rollers.
3. Programming: Set profile length, batch quantity, and punch patterns on PLC.
4. Start and Monitor: Activate machine and monitor output. Use emergency stop if anomalies occur.
5. Output Handling: Stack profiles manually or with automatic stackers.

Cost Range (USD)

• Low-End: $25,000 – $60,000 (manual decoilers, slower speeds)
• Mid-Range: $60,000 – $120,000 (semi-auto, good for most use cases)
• High-End: $120,000 – $300,000+ (full automation, high precision, multi-profile capability)

Top U.S. Roll Forming Machine Manufacturers

• Samco Machinery (U.S. & Canada)
• Bradbury Group
• Formtek Group (including brands like Yoder)
• Metform International
• Englert Inc.

These companies produce machines both for standard and highly specialized roll forming lines.

Why Machine Matcher Is Your Best Buying Partner

Machine Matcher works with hundreds of manufacturers and dealers across the U.S. and globally to help you match your ideal machine to your specific profile, production needs, budget, and industry standards.

• New and used machines
• Technical consulting and sourcing support
• Profile matching service
• Trusted international logistics and delivery
• Access to hard-to-find or discontinued models

Contact Machine Matcher:

• UK: +44 20 335 56554
• USA: +1 407 559 7948
• Europe: +32 460 24 13 95
• WhatsApp: +44 20 335 56554
• Email: [email protected]

Questions and Answers

Q: How do I choose the right roll forming machine for my business?
A: Start with your profile type, production volume, and available space. Contact Machine Matcher to help guide you based on your specs.

Q: How long does it take to set up a new machine?
A: Setup usually takes 3–5 days including calibration and testing, depending on the machine’s complexity.

Q: Can I use one roll forming machine for multiple profiles?
A: Yes, with adjustable or cassette-type roll formers. These are typically higher-cost but ideal for flexible production.

Q: Are used roll forming machines reliable?
A: Yes—if sourced from a reputable dealer or platform like Machine Matcher, used machines can offer excellent value and performance.

Q: What power requirements do U.S. machines typically need?
A: Most use 3-phase 220V or 440V depending on the factory setup.

Looking to buy the best roll forming machine for your business in the U.S.? Let Machine Matcher do the hard work for you.

Visit us at www.machinematcher.com or contact us today.