Every minute a roll forming line stops, factories lose money. Whether you manufacture roofing sheets, purlins, decking, flashing, or metal framing, electrical faults are one of the most expensive and disruptive problems in any production environment.

Typical downtime costs for medium-sized metal fabrication factories:

• $800–$3,500 per hour in lost production

• Missed delivery deadlines

• Scrap material produced when restarting

• Higher labor cost due to idle operators

• Damage to customer reputation

Across hundreds of machines supported globally, Machine Matcher has identified one common trend:

Over 70% of roll forming downtime is caused by electrical faults — not mechanical problems.

And that’s where our dedicated electrical technician team delivers measurable results.

Why Electrical Faults Cause Most Downtime

Electrical issues don’t just stop the machine; they create unpredictable, intermittent behavior that is difficult for factory operators to diagnose.

Common downtime-causing faults include:

• Encoder failures

• VFD trips (overload, overvoltage, undervoltage, OL1/OL2)

• Loose terminals

• Burnt wiring

• Incorrect grounding

• Faulty sensors

• Hydraulic solenoid wiring faults

• PLC I/O failures

• Power supply instability

• Frequency mismatch

• Safety relay trips

• Emergency stop failures

Without proper electrical diagnostics, factories typically spend:

• Hours resetting the machine

• Half a day replacing parts that weren’t faulty

• Additional downtime waiting for a local electrician

Machine Matcher eliminates all of that.

How Machine Matcher Reduces Downtime by 60% (Verified Across Hundreds of Sites)

We achieve this through a structured, highly engineered diagnostic system that most factories have never had access to before.

1. Expert Electrical Diagnosis Instead of Guesswork

Most machine stops happen due to hidden electrical problems — not visible mechanical issues.

Machine Matcher electrical technicians perform:

• PLC input/output tracing

• Encoder pulse measurement

• VFD diagnostics & parameter verification

• Sensor signal quality tests

• Grounding & shielding inspection

• Overload and protection analysis

• Control voltage stability measurement

• Thermal imaging to detect hotspots

• Full safety circuit validation

This eliminates unnecessary part replacement and identifies the root cause immediately.

Result:
✔ Faster fixes
✔ Less scrap
✔ No more repeated faults

2. High-Speed Remote Support (24/7)

Instead of waiting 1–3 days for a local technician, Machine Matcher provides:

• Instant video diagnosis

• PLC screenshot analysis

• VFD parameter review

• Sensor and encoder testing over camera

• Remote guidance for your operators

• Emergency restart assistance

Most electrical issues are diagnosed within 15–45 minutes.

Result:
✔ Downtime reduced by up to 40%
✔ No travel cost
✔ No waiting for contractors

3. On-Site Electrical Technicians When Needed

For complex problems, we dispatch trained roll forming electrical specialists — not general electricians.

Technicians can perform:

• Full panel rewiring

• Encoder replacement & calibration

• Safety relay upgrades

• Cable replacement

• Rebuilding terminal blocks

• Installing new PLC/VFD hardware

• Eliminating electrical noise & interference

General electricians often misdiagnose roll forming faults.
Machine Matcher sends industry specialists who know these machines inside out.

Result:
✔ Problems solved correctly the first time
✔ Significantly shorter repair cycles

4. Preventive Electrical Maintenance Plans

Most electrical failures show warning signs weeks before the machine stops.

Machine Matcher preventive plans include:

Monthly

• Terminal tightening

• Sensor cleaning & testing

• Power supply checks

Quarterly

• Encoder alignment & calibration

• VFD cooling and fan inspection

• Panel dust removal

• Safety circuit testing

Annually

• Full wiring audit

• Thermal imaging

• Grounding verification

• Replacement of weak components

Factories using our preventive plan see:

• 60% fewer electrical faults

• Lower scrap rate

• Higher accuracy of cut lengths

• Longer component life (power supplies, VFDs, sensors)

5. Real Case Studies (Short Examples)

Case Study 1: USA — Roof Panel Line

Problem: Machine stopping randomly 6–8 times per day
Cause: Loose 24VDC terminals + sensor noise
Fix: Terminal tightening, grounding correction, cable reroute
Downtime reduction: 70% within 24 hours

Case Study 2: UK — C Purlin Line

Problem: Incorrect lengths, encoder glitching
Cause: Damaged encoder cable + grounding issue
Fix: New shielded cable + proper earth bonding
Downtime reduction: 60%

Case Study 3: Middle East — Decking Line

Problem: VFD overvoltage trip every shift
Cause: Incoming power fluctuations
Fix: Surge suppressor + line reactor installation
Result: Zero VFD trips for 6 months

6. Why Our Technicians Perform Better Than General Electricians

Because roll forming electrical systems are unique.

A typical electrician may not understand:

• PLC ladder logic

• VFD acceleration curves for flying shears

• Torque compensation for heavy-gauge material

• Encoder pulse timing for punching

• Inductive sensor noise on long lines

• 24VDC stability under load

• Safety relay logic and feedback loops

Machine Matcher electrical engineers specialize exclusively in roll forming machines, covering all brands, PLC types, VFD types, and machine sizes.

7. Remote Support + On-Site Support = Maximum Uptime

Your factory gets full coverage:

Remote Support

• Immediate diagnosis

• Video troubleshooting

• PLC/VFD review

• Sensor & encoder verification

• Restart assistance

On-Site Support

• Rewiring

• Safety system upgrades

• Motor & solenoid wiring repairs

• Control panel rebuilds

• Machine commissioning

When combined, factories see downtime reduced by up to 60% consistently.

Machine Matcher CTA — Annual Preventive Electrical Maintenance Plan

You can now enroll your factory in Machine Matcher’s Annual Electrical Preventive Maintenance Program, which includes:

• Monthly remote electrical checks

• Quarterly on-site inspections

• Annual full wiring audit

• VFD & PLC performance review

• Encoder and sensor calibration

• Control panel cleaning

• Grounding & terminal tightening

• Full written diagnostic report

• 24/7 priority remote support

Reduce downtime by 60%.
Increase accuracy.
Protect your electrical systems.
Keep your roll forming line running — every day of the year.

Machine Matcher now offers full electrical technician services for roll forming machines — including diagnostics, rewiring, testing, encoder calibration, PLC programming, electrical audits, and preventive maintenance.
We support all machine types and all global regions.
Contact us today for immediate technical assistance or to schedule a full electrical inspection at your factory.

Looking for the right roll forming machine or expert guidance on your next project? Machine Matcher is here to help. Our global team provides 24/7 technical support, expert advice, and guidance on machine selection, setup, and maintenance—ensuring your operations run smoothly from day one.

With team members based worldwide—including the UK, USA, Middle East, and beyond—we are equipped to assist buyers across the globe. Whether you’re sourcing a single machine or upgrading an entire production line, our experts are ready to provide tailored solutions and support every step of the way.

Get in touch now and let Machine Matcher help you find the perfect roll forming machine for your business.

United Kingdom (Main Office)
Phone: +44 20 335 56554

United States
Phone: +1 407 559 7948

Mobile / WhatsApp: +44 7816 972935

Email: [email protected]