The Double Hat Channel Roll Forming Machine is a high-efficiency metal forming system developed for manufacturers who need to produce different hat-shaped steel profiles without installing two separate production lines. By combining two forming configurations into one production system, the machine provides a practical solution for reducing equipment costs, saving factory space, and improving manufacturing flexibility.

Also known as a Dual Profile Hat Channel Machine or Two Profile Hat Furring Channel Roll Former, this equipment is mainly used to manufacture galvanized steel channels for drywall, ceilings, wall systems, steel framing, cladding, and other construction applications.

With automatic feeding, roll forming, punching, flying cutting, and PLC control integrated into one line, the machine can provide continuous and stable production with consistent profile dimensions.

Dual-Profile Production from One Roll Forming Line

A major feature of this dual-profile hat channel roll forming machine is its ability to manufacture two different product specifications on the same production line.

For manufacturers producing multiple channel sizes, this configuration offers several practical benefits compared with purchasing two independent machines:

• One production line for two hat channel profiles

• Lower initial equipment investment

• Reduced factory floor space

• Fewer operators required

• Centralized electrical and hydraulic control

• Easier machine maintenance

• Flexible production according to customer orders

The two profile configurations can be customized according to the customer's drawings and production requirements. Before manufacturing, our engineers can confirm the material thickness, profile dimensions, hole patterns, and finished product specifications.

What Are Hat Furring Channels Used For?

A hat channel is a lightweight cold-formed steel member featuring a distinctive hat-shaped cross section. The profile provides good structural rigidity while keeping material consumption relatively low.

Galvanized hat channels are widely used in:

• Drywall ceiling systems

• Interior wall framing

• Furring systems

• Suspended ceilings

The galvanized surface also provides improved resistance to corrosion, making these profiles suitable for long-term use in construction environments.

Complete Hat Channel Manufacturing Process

The Hat Furring Channel Roll Forming Machine combines several processing stages into a continuous production line. The steel coil enters the machine through the decoiling and feeding section and is gradually formed into the required profile.

The standard configuration includes:

1. 1.5-ton decoiler

2. Feeding and guiding system

3. Roll forming section

4. Turkish straightening system

5. Hydraulic punching unit

6. Servo hydraulic flying shear

7. Delta PLC control cabinet

8. Automatic product discharge and collection table

This integrated configuration reduces manual handling and allows the operator to manage the entire production process from the control panel.

The PLC touchscreen can be used to set production length, quantity, machine speed, and other operating parameters.

Heavy-Duty Forming Frame

For continuous metal profile production, the rigidity of the forming machine directly affects product quality. This Double Hat Channel Roll Former uses a vertical arch-type frame structure designed to provide stable support for the forming rollers.

Each profile is processed through 11 forming stations, allowing the galvanized steel strip to be progressively shaped rather than being bent aggressively at one point.

The roller system uses quenched Cr12 tool steel, offering good hardness and wear resistance for long-term production.

The forming shafts are manufactured from 45# tempered steel and have a diameter of 50 mm. A gear-driven transmission system is used to synchronize the forming stations and provide stable power transfer.

Servo Flying Shear for Continuous Production

The cutting section is equipped with a servo hydraulic flying cutting system. Unlike traditional stop-and-cut systems, the flying shear can cut the formed profile while the production line continues running.

This configuration is particularly useful when higher productivity is required.

The cutting system provides:

• Cutting accuracy of approximately ±1 mm per 3 meters

• Continuous cutting operation

• Reduced production interruption

• Clean cutting edges

• Low profile deformation

• Reduced material waste

• Long blade service life

The cutting blades are manufactured from GB Cr12 tool steel, which is suitable for repeated cutting operations.

The final cutting parameters can be programmed through the PLC system according to the required product length.

Material and Production Capability

The Dual Profile Hat Channel Machine is designed primarily for galvanized steel coils used in light steel construction and ceiling systems.

The standard production range includes:

Specification	Technical Data
Processed Material	Galvanized Steel
Material Thickness	0.3–0.6 mm
Maximum Coil Width	Up to 350 mm
Decoiler Capacity	1.5 Tons
Forming Stations	11 + 11
Production Speed	0–40 m/min
Cutting Accuracy	±1 mm / 3 m

Actual machine specifications can be adjusted according to the customer's profile drawings and production requirements.

Intelligent PLC Control System

The production line uses a Delta PLC control system together with a Delta inverter and Omron encoder.

The operator can manage the major production parameters through the touchscreen interface, including:

• Target production length

• Cutting quantity

• Machine running speed

• Automatic stop settings

• Production data

• Manual and automatic operating modes

Electrical components from Schneider are used in the control system to provide reliable operation during continuous production.

This level of automation helps reduce operator workload and makes the machine easier to operate for both experienced and new production staff.

Why Use a Two-Profile Hat Channel Machine?

For manufacturers with different customer orders, producing only one profile can limit production flexibility. A two-profile roll forming line allows the factory to manufacture two hat channel designs while using a shared production system.

1. Lower Equipment Investment

One machine can perform the work of two individual production lines, helping reduce the initial investment in forming equipment.

2. Better Use of Factory Space

Combining two production capabilities into one line reduces the amount of floor space required for machinery.

3. Flexible Product Manufacturing

Different hat channel dimensions can be produced according to project requirements, making the machine suitable for manufacturers serving multiple markets.

4. Automated Production

Automatic feeding, forming, punching, cutting, and control reduce manual intervention throughout the production process.

5. Stable Forming Quality

The heavy-duty frame, precision rollers, geared transmission, and progressive forming process help maintain consistent product dimensions.

6. Reduced Labor Requirements

The automated production line allows fewer operators to manage routine manufacturing operations.

Applications of the Double Hat Channel Roll Former

The finished profiles can be used in a wide range of construction and industrial applications.

Typical applications include:

Drywall Framing:
Hat-shaped furring channels can be used as supporting members in drywall wall and ceiling systems.

Ceiling Systems:
The channels provide a lightweight framework for suspended and decorative ceiling installations.

Wall Cladding:
Hat profiles can function as secondary support members behind metal cladding and wall panels.

Light Steel Construction:
The machine can produce lightweight steel framing components for various building projects.

Solar Structures:
Depending on the profile design and load requirements, hat-shaped steel sections can be used as auxiliary members in solar mounting structures.

Technical Support from Zhongtuo

Zhongtuo provides more than just the Hat Furring Channel Roll Forming Machine. Our engineering team can assist customers throughout the machine selection, design, production, installation, and commissioning stages.

The service can include:

• Profile drawing confirmation

• Roll forming machine design

• Machine manufacturing

• Factory testing

• Installation guidance

• Operator training

• Remote technical support

• Overseas commissioning service

• Production troubleshooting

Before production, customers can provide their hat channel profile drawings or samples. Our engineers can then recommend the appropriate forming configuration and machine specifications.

Technical Specifications of Dual Profile Hat Channel Machine

Parameter	Specification
Machine Type	Double Hat Channel Roll Forming Machine
Production Mode	Two Profiles / One Line
Material	Galvanized Steel
Thickness	0.3–0.6 mm
Coil Width	≤350 mm
Decoiler	1.5 Ton
Forming Stations	11 + 11
Roller Material	Cr12 Quenched
Shaft Material	45# Tempered Steel
Shaft Diameter	50 mm
Main Power	7.5 kW
Hydraulic Power	5.5 + 5.5 kW
Servo Power	1.5 + 1.5 kW
Maximum Forming Speed	40 m/min
PLC	Delta
Inverter	Delta
Encoder	Omron
Electrical Components	Schneider
Cutting Method	Servo Hydraulic Flying Cutting
Cutting Accuracy	±1 mm / 3 m

The Double Hat Channel Roll Forming Machine provides an efficient solution for manufacturers that need to produce multiple galvanized steel hat profiles while keeping equipment investment and factory space under control.

With dual-profile production, 11+11 forming stations, Cr12 forming rollers, servo hydraulic flying cutting, and Delta PLC automation, the production line is designed for stable, continuous manufacturing of hat furring channels and related steel profiles.

For customers looking for a Dual Profile Hat Channel Machine, Two Profile Roll Forming Line, or Hat Furring Channel Roll Former, Zhongtuo can customize the machine according to profile drawings, material specifications, punching requirements, and production capacity.

Send us your hat channel profile drawing or sample, and our engineers can recommend a suitable roll forming solution for your production line.