R101 Trapezoidal Roof Sheet Roll Forming Machine | Automatic Line

The ZTRFM R101 Trapezoidal Roof Sheet Roll Forming Machine is a fully automatic production line developed for manufacturing R101 and similar trapezoidal metal roofing panels. The R101 profile is widely used in Mexico, Costa Rica, Honduras, Guatemala, Colombia and other Latin American markets for industrial roofing, warehouses, workshops, commercial buildings and steel structure projects.

The machine integrates uncoiling, feeding, guiding, roll forming, automatic length measuring, hydraulic cutting and finished sheet receiving. After the operator enters the required production length and quantity through the PLC touch screen, the line can operate automatically, helping roofing sheet manufacturers improve production efficiency and maintain consistent profile quality.

R101 and R72 Profile Production

One important advantage of this production line is its flexible material feeding design. The machine can process different coil widths according to the required finished profile.

For the R101 roofing panel, the typical feeding width is 1220 mm. The finished R101 profile has eight main waves. For R72 production, a 914 mm feeding width can be used to produce a six-wave profile. Different raw material widths can be fed into the same designed production line according to the confirmed profile specification.

The machine is suitable for producing trapezoidal roofing sheets based on TERNIUM-style standards and can also be customized according to customer drawings.

Suitable Raw Materials

The machine can process a variety of coated steel coils commonly used in the roofing industry, including:

• PPGI pre-painted galvanized steel

• PPGL pre-painted Galvalume steel

• GI galvanized steel

• GL / Aluzinc steel

• Color-coated steel coil

The typical processing thickness range can be designed from approximately 0.3 to 0.7 mm, depending on the profile, steel grade and customer requirements. Material yield strength and coating specifications should be confirmed before machine production to ensure the roller design matches the actual raw material.

Production Process

The complete working flow is:

Uncoiling → Feeding → Guiding → Roll Forming → Length Measuring → Hydraulic Cutting → Finished Product Receiving

The production line is designed for continuous automatic operation. Once the production parameters are set, the PLC coordinates the main motor, encoder and hydraulic cutting system to manufacture roofing sheets according to the required length and quantity.

Heavy-Duty Machine Frame

The standard machine can use a 350 mm H-beam base structure combined with welded steel supporting plates. This heavy-duty structure provides good rigidity during continuous roll forming and helps reduce machine vibration.

A stable machine frame is important for maintaining roller alignment, finished sheet straightness and consistent profile dimensions during long production runs.

Precision Roll Forming System

A typical R101 machine uses approximately 21 forming stations. The steel sheet is gradually shaped through each roller station instead of being formed in one step.

This progressive forming process helps control material deformation and produces a more consistent trapezoidal profile.

The forming rollers are normally manufactured from high-grade 45# steel and precision machined. The surface can be hard chrome plated to improve hardness, wear resistance and service life while helping reduce damage to the coated surface of PPGI and PPGL materials.

Strong Solid Shafts

The forming shafts use high-grade steel with heat treatment. A typical configuration uses approximately Φ80 mm solid shafts.

The strong shaft structure provides reliable support for the forming rollers and helps maintain alignment during production. Shaft size and forming station quantity can also be adjusted according to material thickness, profile depth and production speed.

Double Chain Transmission

The standard R101 roofing sheet machine uses a double-chain transmission system combined with gears.

Compared with a simple single-chain structure, the double-chain design provides more stable transmission between forming stations and helps distribute driving force during continuous production.

Each forming roller is securely positioned on the shaft to improve operational stability and reduce unwanted movement during forming.

Adjustable Feeding Device

The feeding section is designed to guide the steel coil accurately into the roll forming machine.

Hand wheels on both sides allow the feeding width to be adjusted. Stainless steel guiding rollers help the material enter the machine smoothly while reducing direct friction against the coated surface.

Proper feeding alignment is especially important for trapezoidal roofing panels because incorrect material positioning can affect the final effective width and side overlap.

Automatic Hydraulic Cutting

After the R101 profile is completely formed, the finished panel passes to the hydraulic cutting section.

The standard line uses hydraulic post cutting. A four-pillar cutting structure can be adopted to improve cutting stability and guide the blade accurately during operation.

The cutting blade is manufactured from high-strength tool steel with heat treatment to improve hardness and working life. The blade profile is designed according to the finished roofing sheet shape.

The encoder continuously measures the panel length. When the preset length is reached, the PLC sends a cutting signal to the hydraulic system and the sheet is cut automatically.

PLC Control System

The complete production line is controlled through an industrial PLC system.

Typical electrical configuration includes:

• Delta PLC

• Delta touch screen

• Delta inverter

• Omron encoder

• Schneider electrical components

Operators can set the required roofing sheet length and production quantity directly on the touch screen. The operating language can be supplied in English, Chinese or customized according to customer requirements.

Aviation plugs can also be used between different machine sections to simplify electrical installation after the machine arrives at the customer's factory.

Main Technical Configuration

Raw Material: PPGI, PPGL, GI or coated steel
Typical Thickness: 0.3–0.7 mm
R101 Feeding Width: Approx. 1220 mm
R72 Feeding Width: Approx. 914 mm
Forming Stations: Approx. 21 rows
Shaft Diameter: Approx. Φ80 mm solid shaft
Shaft Material: High-grade 45# steel with heat treatment
Roller Material: 45# steel with chrome-plated surface
Standard Forming Speed: Approx. 15 m/min
Main Motor: Approx. 5.5 kW
Transmission: Gear and double-chain transmission
Cutting Type: Hydraulic post cutting
Voltage: 380V / 50Hz / 3 Phase or customized
Control System: PLC + Touch Screen

Technical specifications can be adjusted according to the customer's final drawing, raw material and production requirements.

Decoiler and Receiving System

The standard line can be equipped with a 5-ton manual decoiler. A typical decoiler supports coil inner diameters of approximately 450–550 mm and feeding widths up to about 1220 mm.

For customers who require easier coil loading or a higher level of automation, hydraulic decoilers, loading trolleys and automatic feeding systems can be supplied as optional equipment.

A standard receiving table can be installed after the cutting section, while an automatic stacker can be added for higher-production factories.

Customized Roofing Sheet Solutions

Different countries use different trapezoidal roofing profiles. ZTRFM can manufacture the roll forming machine according to the customer's own roofing sheet drawing.

Customization can include:

• Roofing profile dimensions

• Material thickness

• Coil feeding width

• Production speed

• Number of forming stations

• Shaft diameter

• Transmission system

• Hydraulic or servo cutting

• Decoiler type

• Automatic stacker

• PLC and electrical brands

• Voltage and frequency

• Touch-screen operating language

Customers can provide a finished panel drawing with complete dimensions for technical evaluation before production.

Applications of R101 Roofing Sheets

R101 trapezoidal roofing panels can be used for industrial factories, warehouses, workshops, agricultural buildings, logistics centers, steel structure buildings, commercial facilities and residential roofing.

The trapezoidal rib design provides good structural strength while keeping the roofing panel lightweight. Different colors, coatings and sheet lengths can be produced according to local building requirements.

Machine Testing and Quality Control

Before shipment, the complete production line can be assembled and tested in the factory. The inspection process includes roller alignment, transmission operation, hydraulic cutting, electrical control, PLC settings, finished profile dimensions and cutting length.

Steel coils are fed through the machine to check the actual forming result. Customers can also provide their own raw material for testing when required.

After-Sales and Technical Support

ZTRFM provides technical support for machine installation, operation, adjustment and maintenance. Operating manuals, electrical diagrams and remote video guidance can be supplied with the machine.

Engineer installation and commissioning services can also be arranged according to project requirements. Spare parts and long-term technical consultation are available to support customers during future production.

For an accurate quotation and machine solution, customers are recommended to provide the roofing sheet profile drawing, raw material type, material thickness, coil width, required production speed, local voltage and desired automation level.