Hat Channel Roll Forming Machine Omega Furring Line Automatic Hat Channel / Furring Channel Line (40 m/min)

Overview

Automatic Hat Channel Roll Forming Machine with 3D finished Omega furring channel sample, CAD cross-section drawing and technical parameter badges

The Zhongtuo Automatic Hat Channel Roll Forming Machine (also recognized globally as Omega Furring Channel Making Line / Ceiling Batten Roll Former) is a heavy-duty, high-precision automated manufacturing solution engineered for continuous production of top-hat furring channels, drywall ceiling battens, and architectural wall framing profiles. Operating at rapid production speeds up to 40 m/min, the machine rolls light-gauge galvanized steel (GI) coil (0.4–1.0 mm thickness) into tight-tolerance hat-shaped channels with clean angles, flat webs, and uniform clip-in mounting flanges.

Built upon a reinforced 350H steel bed with precision-ground 80 mm solid 45# forged steel shafts and vacuum-quenched Cr12 tool steel rollers, the line incorporates a multi-station hydraulic punching unit (pre-shearing, 14×30 mm and 8×20 mm slotted die sets), an automatic drip-oil lubrication unit, an integrated pattern knurling/embossing station, and an advanced servo tracking flying cut-off mechanism. Governed by a top-tier imported Siemens/Delta PLC touchscreen console, the system delivers high output, zero burr cutting, and non-stop continuous operation for drywall contractors and framing manufacturers.

• Continuous production speed up to 40 m/min powered by a 7.5 kW main motor drive
• Standard hat channel CAD dimensions: top width 35–50 mm, height 20–35 mm, bottom flange 10–15 mm
• Non-stop servo tracking flying cut-off with Cr12 contour shear die ensuring clean, burr-free ends
• Multi-station in-line hydraulic punching (pre-shear, 14×30 mm and 8×20 mm slotting dies)
• Solid 80 mm diameter 45# forged steel shafts with CNC precision-turned Cr12 mould steel rollers
• Automatic drip-oil lubrication device and 1 pair of stiffening pattern embossing rollers included
• Certified to CE, BV, STV and ISO9001 standards; backed by a comprehensive 2-year warranty

Key Features

• Servo Tracking Flying Cut-Off. The cut-off carriage synchronizes dynamically with moving steel strip velocity using a high-response servo drive, executing precise non-stop shearing without slowing or stopping the forming stations.
• Integrated Multi-Die Hydraulic Punching. Incorporates three dedicated hydraulic die stations—pre-shearing unit, 14×30 mm slot die set, and 8×20 mm slot die set—allowing versatile in-line punching for suspension hangers and screw fastenings.
• Heavy 80 mm Forged Solid Shafts. Extra-heavy 80 mm solid No.45 steel shafts are tempered, quenched, and fine-ground to eliminate shaft flexing and preserve microscopic roll clearance during full-gauge continuous runs.
• Cr12 Mould Steel Forming Tooling. Rollers are crafted from certified Cr12 alloy tool steel, precision-turned on CNC lathes, and vacuum-quenched to HRC 58–62 for long life and scratch-free rolling on galvanized coils.
• In-Line Embossing & Automatic Oiling. Built-in knurling rollers impress reinforcing dimples across the web to increase load-bearing capacity and prevent drywall screws from walking, while the auto-oiler extends roller life.
• Imported Siemens / Delta PLC Control. Industrial color touch screen allows quick order input, automatic batch tallying, multi-speed ramping, and real-time fault diagnostics.
• Heavy A-Frame Uncoiler Station. Sturdy decoiler handles industrial-weight galvanized coils smoothly, ensuring reliable strip tension throughout high-speed operations.

Technical Specifications

Machine Structure

The automated processing line commences at the heavy A-frame decoiler, continuously unwinding light-gauge galvanized coil through guide rolls into the multi-die punching zone. Here, high-pressure hydraulic cylinders punch suspension slots (8×20 mm and 14×30 mm) and execute pre-shearing if required. The strip then enters the primary forming bed, passing sequentially through knurling rolls and precision Cr12 roller stands driven by heavy 80 mm solid steel shafts. Finally, the shaped hat section is severed on the fly by a dedicated profile shear die mounted on a servo-synchronized carriage.

Front elevation of the heavy-duty hydraulic shear head showing the custom hat profile contour die aperture and guide pillars

High-speed hydraulic multi-station punching unit displaying pre-shearing die, 14×30 mm die set B, and 8×20 mm die set A with proximity sensors

Detailed workshop view of numbered Cr12 mould steel forming stations mounted on heavy 80 mm solid forged shafts with dual gear drives

Heavy-duty grey A-frame uncoiler assembly holding a wide galvanized master coil feeding directly into the roll forming bed

Profile CAD & Applications

Hat channels (Omega furring sections) provide indispensable structural support and leveling across modern building interior and exterior envelope systems:

• Suspended Drywall Ceilings. Serves as rigid secondary battens fastened beneath primary carrying channels or concrete floor slabs to support gypsum board panels.
• Masonry & Concrete Wall Furring. Mechanically anchored to concrete block or masonry walls to create a level, air-spaced sub-frame for thermal insulation and drywall panels.
• Architectural Facade Sub-Girts. Utilized as horizontal or vertical rainscreen sub-framing for external metal cladding and composite wall panels.
• Acoustic Ceiling Suspension Grids. Engineered with anti-slip knurled surfaces for rapid screw engagement and vibration-resistant acoustic ceiling assemblies.

Quality & Certifications

Manufactured in full conformity with ISO9001 quality management procedures and European CE Machinery Directive regulations, every machine is subjected to a rigorous 24-hour continuous trial rolling test prior to factory dispatch. Certified third-party verification documents (UDEM, COTECNA) and video outgoing-inspection records accompany every delivery.

Official international certification gallery: CE Machinery Directive compliance documents and ISO9001 certified manufacturing credentials

Customization Options

Packaging & Delivery

FAQ

What are the operational advantages of servo tracking cutting on hat channel machines?

Traditional stop-and-cut systems force the line to halt completely for every cut, causing material deceleration, motor stress, and reduced daily output. Servo tracking cutting moves synchronously with the strip to execute clean cuts without stopping, maximizing speed up to 40 m/min with ±1 mm length precision.

What functions do the multi-station hydraulic punching dies perform?

The punching assembly incorporates pre-shearing and two standardized slotted die sets (14×30 mm and 8×20 mm). These punch suspension and fastening slots directly into the flat strip prior to roll forming, ensuring perfectly aligned holes without burrs or deformed profile walls.

Why are heavy 80 mm solid shafts important for furring channel production?

Omega channels feature multiple crisp bends and tight return hems. Heavy 80 mm forged solid No.45 steel shafts provide the torsional rigidity required to prevent roll deflection, ensuring razor-sharp 90-degree bends and consistent clip-in dimensions across high-speed runs.

How does the automatic lubrication system benefit production?

The automated drip oiler applies a controlled film of forming oil to the coil before it reaches the forming stations. This minimizes roll friction, prevents zinc coating galling or scratching, and dramatically extends roller tooling service life.

What coil thickness and material grades can be processed?

The machine standardly handles 0.4 mm to 1.0 mm thickness (compatible up to 1.2 mm) in commercial hot-dip galvanized steel (GI), aluzinc, and cold-rolled steel coils with yield strengths up to 550 MPa.

What warranty and technical support are included with the machine?

The line includes a full 2-year warranty covering non-wearing mechanical and electrical parts, supported by lifetime technical assistance. Video outgoing inspections, comprehensive test reports, operational manuals, and engineer on-site commissioning services are available worldwide.