Roll Forming vs Tube Mill Forming: Cost, Speed, Profiles & Production Comparison

Roll Forming vs Tube Mill Forming

1. Overview of Both Technologies

What is Roll Forming?

Roll forming is a continuous cold-forming process where metal coil is passed through multiple roll stations to produce a constant cross-section profile.

• Coil-fed continuous production
• High-speed and automated
• Designed for open profiles

Typical products:

• Roofing and cladding panels
• C & Z purlins
• Cable trays
• Metal studs and structural sections

What is Tube Mill Forming?

Tube mill forming is a continuous process used to produce closed sections, such as pipes and tubes, from steel strip.

• Coil-fed process
• Forms strip into a round or square shape
• Includes welding (ERW – Electric Resistance Welding)

Typical products:

• Steel pipes and tubes
• Square and rectangular hollow sections
• Structural tubing
• Automotive tubing

2. Engineering Explanation

Roll Forming Engineering

• Progressive bending through multiple roll stations
• No welding involved
• Open profiles are formed gradually
• Maintains consistent material thickness

Key Outcome:
Ideal for open-section profiles with consistent geometry

Tube Mill Engineering

• Steel strip is progressively formed into a round shape
• Edges are brought together and welded
• Tube is then sized and shaped (round, square, rectangular)
• Includes inline cutting

Key Outcome:
Ideal for closed-section profiles with high structural strength

3. Cost Comparison

This section compares roll forming and tube mill forming across key cost factors.

Machine Investment

Roll forming requires a high investment (typically £50k–£500k+), depending on the complexity of the line.
Tube mill lines require a higher investment (often £150k–£1M+), due to welding systems and sizing equipment.

Tooling Cost

Roll forming has medium to high tooling costs, with dedicated roll sets for each profile.
Tube mill tooling costs are also high, especially for sizing rolls and different tube dimensions.

Cost per Part

Roll forming delivers a very low cost per part at high production volumes.
Tube mill forming also achieves a low cost per unit, particularly for high-volume pipe and tube production.

Labour Cost

Roll forming has low labour requirements, with automated operation.
Tube mills also operate with low labour, but require more technical oversight due to welding systems.

Material Efficiency

Roll forming offers high efficiency, with minimal waste.
Tube mills also have high efficiency, though some material is lost during edge trimming and welding.

Key Insight

Roll forming is best suited for open profiles, while tube mill forming is designed specifically for closed sections such as pipes and structural tubing.

4. Production Speed Comparison

Roll Forming

• Continuous production
• Speeds: 30–120 meters per minute
• No interruptions

Highly efficient for open profiles

Tube Mill Forming

• Continuous production
• Speeds: typically 20–80 meters per minute depending on size and thickness
• Includes welding and sizing stages

Efficient but slightly slower due to welding process

Conclusion

Roll forming is generally faster for open profiles, while tube mills maintain high speed despite additional welding steps.

5. Maintenance Comparison

Roll Forming

• Roll tooling maintenance
• Bearings and gearbox servicing
• Alignment checks
• Long tooling lifespan

Predictable maintenance

Tube Mill Forming

• Roll tooling maintenance
• Welding system maintenance
• Cooling system checks
• Higher wear due to heat and welding

More complex maintenance requirements

6. Typical Industries

Roll Forming Industries

• Construction (roofing, cladding, framing)
• Solar mounting systems
• Storage and racking
• Infrastructure

Tube Mill Industries

• Oil and gas
• Construction and structural steel
• Automotive manufacturing
• Furniture and equipment manufacturing

7. Advantages and Disadvantages

Roll Forming

Advantages

• High production speed
• Low cost per part
• Consistent quality
• Minimal waste
• Ideal for open profiles

Disadvantages

• Cannot produce closed sections
• Limited flexibility
• High setup cost

Tube Mill Forming

Advantages

• Produces closed sections (pipes and tubes)
• High structural strength
• Continuous production
• Suitable for a wide range of sizes

Disadvantages

• Requires welding
• Higher machine complexity
• More maintenance
• Slightly slower than roll forming

8. When to Choose Each Option

Choose Roll Forming When:

• You need open profiles
• Production volume is high
• Profiles are long and consistent
• Cost per unit is critical

Example: Roofing panels, purlins

Choose Tube Mill Forming When:

• You need closed sections
• Structural strength is important
• Pipes or hollow sections are required

Example: Steel tubing and pipes

9. Real Production Examples

Example 1: Roofing Panel Production

• Product: Corrugated panels
• Volume: High
• Process: Roll forming

Continuous production with consistent profiles

Example 2: Steel Pipe Production

• Product: Round steel pipes
• Volume: High
• Process: Tube mill forming

Continuous production with inline welding

Example 3: Structural Tubing

• Product: Square hollow sections
• Process: Tube mill forming

Used in construction and structural applications

10. FAQ

What is the main difference between roll forming and tube mill forming?

Roll forming produces open profiles, while tube mills produce closed sections using welding.

Can roll forming produce tubes?

No, roll forming cannot produce fully closed sections like tubes.

Which is cheaper?

Both are cost-effective at scale, but it depends on the product type.

Which is faster?

Roll forming is generally faster, as tube mills include a welding stage.

Which is stronger?

Tube mill products are typically stronger due to their closed-section geometry.

Which process should I choose?

Choose roll forming for open profiles and tube mills for pipes and hollow sections.