What PLC Systems Are Used in Roll Forming Machines? Complete Guide
Roll forming machines use PLC (Programmable Logic Controller) systems to control speed, length, cutting, synchronization, and automation. The PLC is essentially the “brain” of the machine.
The most commonly used PLC brands in the roll forming industry are:
- Siemens
- Delta
- Mitsubishi
- Omron
- Schneider Electric
Each has different levels of quality, cost, and global support.
Most Common PLC Systems
Siemens (Premium – Best Overall)
Siemens is considered the highest quality PLC system in roll forming.
Common models:
- Siemens S7-1200
- Siemens S7-1500
Advantages:
- Extremely reliable
- High precision and stability
- Strong global support network
- Widely used in Europe and high-end machines
Best for:
- Industrial and structural machines
- High-end production lines
- Businesses targeting premium markets
Delta (Most Popular – Best Value)
Delta is one of the most widely used PLC systems in roll forming machines.
Advantages:
- Lower cost
- Good performance
- Easy to use
- Widely used in Asia and global export machines
Best for:
- Roofing machines
- Entry-level and mid-range setups
- Startups and cost-sensitive projects
👉 This is the most common PLC you will see on standard machines
Mitsubishi (High Quality – Industrial Use)
Mitsubishi PLCs are known for reliability and performance.
Advantages:
- Strong industrial reputation
- Stable and durable
- Good for automation systems
Best for:
- Structural machines
- Automated production lines
- Long-term industrial use
Omron (Reliable & Flexible)
Omron is widely used in automation systems.
Advantages:
- Reliable
- Good integration with sensors and automation
- Flexible programming
Best for:
- Specialized machines
- Automated systems
Schneider Electric (European Standard)
Schneider PLCs are common in European-built machines.
Advantages:
- Strong quality
- Good integration with industrial systems
Best for:
- European markets
- High-end applications
What the PLC Controls
In a roll forming machine, the PLC controls:
- Machine speed (via inverter/VFD)
- Material length measurement
- Cutting timing (hydraulic or flying shear)
- Encoder feedback
- Safety systems
- Automation sequences
Modern PLC systems are usually connected to:
- Touchscreen HMI (operator interface)
- Sensors and encoders
- Servo motors (in advanced systems)
PLC + HMI (Operator Screen)
Most machines include a touchscreen HMI.
Common brands:
- Siemens HMI
- Delta HMI
- Weintek (very common with Delta systems)
This allows operators to:
- Set lengths
- Adjust speed
- Monitor production
- Diagnose errors
Why PLC Choice Matters
The PLC affects:
- Machine reliability
- Ease of operation
- Troubleshooting
- Spare parts availability
A good PLC system can reduce downtime and improve production efficiency.
Best PLC for Different Budgets
Budget / Startup
- Delta PLC
👉 Best balance of cost and performance
Mid-Range
- Mitsubishi or Omron
👉 Better reliability and automation
High-End / Industrial
- Siemens
👉 Best overall performance and global support
Common Mistake (Important)
Many buyers focus only on machine price and ignore the PLC.
This can lead to:
- Difficult troubleshooting
- Limited support
- Compatibility issues
👉 Always check PLC brand before buying
Frequently Asked Questions
What is the most common PLC in roll forming machines?
Delta is the most widely used globally.
Which PLC is the best?
Siemens is generally considered the best for performance and reliability.
Do all machines use PLC systems?
Yes, modern roll forming machines rely on PLC control.
Can PLC systems be upgraded?
Yes, but it can be costly and require reprogramming.
Final Answer (Simple)
👉 The most common PLC systems used are:
- Delta (most popular)
- Siemens (best quality)
- Mitsubishi (industrial reliability)
- Omron / Schneider (specialized use)
👉 For most businesses:
- Start with Delta (cost-effective)
- Upgrade to Siemens (high-end production)