Double Layer PBR & AG Panel Roll Forming Machine

The Double Layer PBR & AG Panel Roll Forming Machine is a high-efficiency roll forming solution designed to produce two popular metal panel profiles with one integrated machine.

The double-layer design allows the machine to produce PBR panels and AG panels, helping manufacturers reduce equipment investment and production space while maintaining stable forming performance and high panel precision.

The lower layer is designed for PBR roofing panels, while the upper layer produces AG panels commonly used for wall cladding and light roofing applications.

With a forming speed of up to 15 m/min, GCr15 forming rollers, a rigid H-beam machine frame, and a 1-inch double-chain transmission system, the machine is designed for continuous and stable production.

Production Process

Uncoiling → Pre-Cutting → Feeding → Roll Forming → Automatic Cutting → Receiving

The hydraulic decoiler feeds the steel coil into the production line. After pre-cutting and precise feeding, the sheet passes through the forming rollers step by step to achieve the required PBR or AG profile.

After forming, the hydraulic automatic cutter cuts the finished panel to the preset length, and the receiving table collects the finished products.

 Technical Specification:

Machine Type	Double Layer PBR & AG Panel Roll Forming Machine
Profiles	PBR + AG
Machine Structure	350 mm H-beam
Middle Support Plate	20 mm welded steel
Upper Forming Stations	19 rows
Lower Forming Stations	19 rows
Roller Material	GCr15
Shaft Diameter	Φ80 mm solid
Shaft Material	45# steel, heat treated
Forming speed	0–15 m/min
Transmission	1-inch double chain
Main Servo Motor	5.5 kW
Cutting Method	Hydraulic post-cutting
Cutter Material	GCr12, quenched
Bearing Brand	SKF
Receiving Table	3 m

Key Features

1. PBR + AG Double Layer Design, One Machine, Two Profiles

Lower Layer — PBR Panel

PBR (Purlin Bearing Rib) panels are commonly used for metal roofing applications where good waterproof performance, structural strength, and longer spanning capability are required.

Upper Layer — AG Panel

AG (Agricultural) panels are commonly used for wall cladding and light roofing applications, particularly in agricultural buildings and similar structures.

This two-in-one configuration allows manufacturers to switch between different panel production requirements while using one complete roll forming system.

 2. Separate Rolling Design

During the forming process, the separate rolling structure helps release internal stress in the metal sheets, allowing the finished panels to maintain a better shape and higher forming precision.

The machine is equipped with:

GCr15 forming rollers
19 forming stations for the upper layer
19 forming stations for the lower layer
Φ80 mm solid shafts
High-grade 45# steel shafts with heat treatment
Step-by-step forming method

The forming roller material is GCr15, selected for the forming system to provide stable and durable operation.

3. Heavy-Duty Machine Frame 

The main machine frame adopts a 350 mm H-beam structure with a 20 mm welded steel middle support plate.

The machine base frame is reinforced with diagonal braces to improve overall rigidity and stability.

After welding, vibration treatment is used to reduce welding stress. Large-scale planer machining is then applied to help ensure the horizontality and rigidity of the machine frame.

This rigid structure provides a stable foundation for long-term roll forming operation.

4. Stable Transmission System

The forming machine uses a 1-inch double-chain transmission system.

The large chain transmission design helps provide stable power transmission during continuous production and contributes to long service life.

A clutch system is also provided, allowing operators to run only one layer when required. This gives users more flexibility during production and can help reduce unnecessary operation of the other forming layer.

 

5. 6-ton Hydraulic Decoiler with Loading Car

Main Features
Maximum loading capacity: 6 tons
Active uncoiling
Coil inner diameter: Φ450–550 mm
Maximum coil width: 1250 mm
Hydraulic expansion and contraction of the coil mandrel
Four supporting arms
Motor-driven forward/reverse movement
Loading car for easier coil loading
Decoiler movement track length: 8 m
Equipped with press arm

The loading car makes heavy steel coil loading easier and helps improve the convenience of material preparation.

 

6. Material Feeding System

The feeding section is designed to guide the steel sheet smoothly into the forming machine.

Hand wheels on both sides allow adjustment of the feeding width.

Four stainless-steel rollers help guide the material into the machine smoothly while reducing the possibility of surface scratching.

The feeding structure helps maintain stable sheet alignment before the material enters the forming stations.

 7. Automatic Hydraulic Cutting System

The cutter uses GCr12 material with quenched treatment, providing a durable cutting solution for production.

Cutting System
Automatic hydraulic front and back cutter
Hydraulic post-cutting
Double-pillar cylinder driving method
GCr12 quenched cutting blades
Automatic length and quantity control through PLC

The operator can set the required product length and quantity through the PLC control system.

8. Delta PLC Control System

The machine is equipped with a Delta PLC and touchscreen control system.

Electrical Components
PLC & Touchscreen: Delta
Encoder: Omron
Electrical components: Schneider
Operating languages: English / Spanish / Chinese
Buttons: English
Aviation plugs for easier installation
Customer logo can be added

The operator can set production orders directly through the control panel, including product length and quantity.

The PLC control system simplifies daily operation and provides convenient production parameter management.