Many roll forming machines — especially imported ones — are built to the minimum acceptable electrical standard. They run, but the panels are often:

• Poorly labelled

• Noisy

• Hard to maintain

• Prone to VFD faults

• Missing documentation

• Lacking room for expansion

• Vulnerable to power issues

Good panel design is not “nice to have”. It’s a direct investment in uptime, accuracy, and long-term reliability.

Here are the essential panel-quality upgrades every factory should request when ordering or refurbishing a roll forming machine.

1. Line & Load Reactors on VFDs

Reduces harmonics, protects VFDs, and stabilizes motor performance

VFDs (variable frequency drives) are extremely sensitive to poor power quality. Harmonics, spikes, and voltage imbalance cause:

• VFD overheating

• Nuisance trips

• Premature drive failure

• Encoder signal noise

• Motor instability

Why line/load reactors matter

• They filter high-frequency harmonics

• Reduce stress on VFD components

• Protect against rough or unstable incoming power

• Improve motor torque smoothness

• Increase drive lifespan

For factories with welders, compressors, or weak grid supply, this upgrade is essential.

2. Separate Neutral and Earth Bars

Clean panel grounding = stable sensors, stable PLC, stable everything

Many cheap panels incorrectly combine neutral and earth. This creates unpredictable electrical behaviour such as:

• Flickering sensors

• Encoder drift

• Random PLC faults

• Noise in 24VDC circuits

Correct configuration:

• One clearly labelled neutral bar (N)

• One clearly labelled earth/ground bar (PE)

• No mixed connections

• All grounds brought to a single PE point

Proper separation eliminates 80–90% of electrical noise problems.

3. Good, Clearly Labelled Earth Bonding

Everything in the machine must be electrically tied back to the control cabinet

A roll forming line is long, metal, and full of moving parts. Every section must be properly grounded.

What must be bonded:

• Main machine frame

• Decoiler frame

• Run-out tables

• Guarding & covers

• Motor frames

• Gearboxes

• Junction boxes

Why this matters

• Prevents electric shock

• Reduces electrical noise on sensors and encoders

• Makes the machine safer and more stable

• Prevents “mystery faults” that operators cannot diagnose

Most imported machines have weak or missing grounding straps — a major safety hazard.

4. Spare Breakers & Extra DIN Rail Space

Plan for future upgrades — not future headaches

Factories change. You may add:

• New sensors

• Safety devices

• A stacker

• A conveyor

• Lubrication pumps

• A PLC expansion module

If your panel is built with no spare space, you’ll face:

• Difficult upgrades

• Messy wiring

• Overcrowded DIN rails

• Expensive panel modifications

What to request from the builder:

• 3–5 spare MCBs already mounted

• Free DIN rail space for future additions

• Extra terminal blocks

• Additional I/O space in the PLC enclosure

This makes future upgrades simpler, safer, and cheaper.

5. Clear Labels & Updated Electrical Drawings

If your panel isn’t labelled, it cannot be maintained properly.

This is one of the biggest weaknesses of low-cost roll forming machine panels.

What you must insist on:

• Every breaker labelled

• Every relay labelled

• Every contactor labelled

• Every terminal block labelled

• Every cable ferruled with wire numbers

• Labels matching the electrical schematics

And most importantly:

The supplier must update the electrical drawings to show the exact final build.

Why this matters:

• Faster troubleshooting

• Safer maintenance

• No guesswork

• Less downtime

• Easy future modifications

• Prevents wiring mistakes

A panel without updated drawings is a panel that nobody can maintain safely.

Summary — The Small Panel Upgrades That Deliver Big Results

To protect your roll forming machine investment, request:

✔ Line/load reactors on VFDs
✔ Separate neutral & earth bars
✔ Correct frame/guard/motor bonding
✔ Spare breakers + DIN rail space
✔ Clean labels & updated drawings

These upgrades improve:

• Uptime

• Safety

• Reliability

• Accuracy

• Troubleshooting speed

• Machine lifespan

Small cost — massive long-term benefits.

Machine Matcher CTA — Panel Upgrade & Electrical Quality Improvement Service

Machine Matcher provides complete panel-quality upgrade packages for new or existing roll forming machines:

• VFD reactors & filtering

• Grounding & bonding upgrades

• Full relabeling

• Electrical drawing updates

• Breaker segregation

• DIN rail expansion

• Safety circuit enhancements

• 24VDC distribution redesign

• Control panel rewiring

• On-site or remote assessment

Protect your machine. Protect your uptime. Protect your investment.
Upgrade your electrical panel quality with Machine Matcher today.

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]