AG Panel & PBR Panel Double Layer Roll Forming Machine

The ZTRFM AG Panel & PBR Panel Double Layer Roll Forming Machine is an automatic metal roofing production line designed to manufacture two popular roofing profiles on one machine. By integrating AG Panel and PBR/R Panel forming systems into a double-layer structure, manufacturers can expand their product range without installing two separate roll forming lines.

This machine is particularly suitable for roofing sheet factories, metal building suppliers, steel structure companies and construction material manufacturers serving the North American market. Finished AG and PBR panels are widely used for agricultural buildings, warehouses, workshops, commercial buildings, garages, steel structures and residential roofing projects.

Two Roofing Profiles in One Machine

The main advantage of the double-layer design is the ability to produce two different roofing profiles using one machine frame.

The upper and lower forming sections operate independently. When production requirements change, the operator selects the required layer and starts the corresponding production process. There is no need to remove forming rollers or completely rebuild the machine.

Compared with purchasing two independent production lines, this configuration can help reduce workshop space, simplify equipment layout and provide greater flexibility for manufacturers handling different customer orders.

Automatic Production Process

The complete production process includes:

Uncoiling → Feeding → Guiding → Roll Forming → Length Measuring → Automatic Cutting → Finished Panel Receiving

After the steel coil is loaded onto the decoiler, the material is guided into the selected forming layer. Multiple forming rollers gradually shape the flat steel sheet into the required AG Panel or PBR Panel profile.

The PLC control system manages production length and quantity automatically. Once the preset length is reached, the cutting system completes the cutting operation and the finished roofing sheet is discharged to the receiving table.

This automatic workflow reduces manual intervention and makes continuous batch production easier to manage.

Precision Roll Forming Design

Each roofing profile has its own independently designed forming roller system.

The steel sheet passes through a series of forming stations and is gradually shaped into the final trapezoidal profile. Progressive forming helps distribute material deformation more evenly and improves the consistency of rib height, panel width and side overlap.

The forming rollers are precision machined from high-quality steel and can receive surface treatment to improve wear resistance and durability.

A smooth roller surface also helps protect pre-painted steel coatings and reduce unnecessary marks during continuous production.

Strong Double-Layer Structure

Combining two forming systems into one frame requires good structural rigidity.

The main machine uses a heavy-duty welded steel structure designed to support both upper and lower roller stations. A stable frame helps reduce vibration and maintain roller alignment during production.

The compact vertical arrangement also allows two roofing products to be manufactured within approximately the floor space of a single production line, making the machine especially suitable for factories where workshop space is limited.

AG Panel Production

AG Panel is a widely used exposed-fastener roofing profile for agricultural, residential and light commercial buildings.

Its trapezoidal rib structure provides good rigidity while remaining lightweight and easy to install. AG Panels can be used for both roofing and wall cladding and are commonly seen on barns, workshops, garages, storage buildings and metal houses.

The machine can be designed according to the customer's exact AG Panel drawing to ensure the finished profile matches local market requirements.

PBR / R Panel Production

PBR Panel and R Panel are widely used for commercial and industrial metal building systems.

These panels provide strong ribs, practical overlap connections and efficient coverage, making them suitable for larger steel structure projects such as warehouses, factories, logistics buildings and commercial facilities.

The PBR forming layer can also be customized according to the customer's profile dimensions instead of being limited to one fixed standard.

Suitable Metal Materials

The production line can process several materials commonly used for metal roofing, including:

• PPGI pre-painted galvanized steel

• PPGL pre-painted Galvalume steel

• Galvanized steel

• Galvalume / Aluzinc steel

• Color-coated steel coils

• Other suitable roofing materials

Because material properties vary between suppliers and markets, the forming system can be designed according to the customer's actual coil specification.

Providing a finished profile drawing and raw material information before production helps our engineers prepare a more suitable machine solution.

PLC Automatic Control

The machine is equipped with a PLC control system and touch-screen interface.

Operators can input the required panel length, production quantity and batch information directly from the control station. The system then coordinates the forming, measuring and cutting processes automatically.

The control interface can be customized with different languages, while machine voltage and electrical configuration can be designed according to the customer's local factory standard.

Automatic Cutting System

The cutting system works together with the PLC and length measuring device.

After the finished panel reaches the preset length, the machine performs the cutting operation automatically. Cutting blades are manufactured according to the corresponding roofing profile to provide stable cutting while maintaining the shape of the finished sheet.

Different cutting solutions can also be selected according to the required production capacity and automation level.

Flexible Production for Roofing Factories

For roofing sheet manufacturers, product variety is often as important as production capacity.

A factory may receive AG Panel orders today and PBR Panel orders tomorrow. Installing two separate lines requires more investment, additional floor space and more maintenance.

The double-layer machine provides a practical alternative by combining both profiles in one production system. Manufacturers can respond to different customer requirements while keeping the equipment arrangement relatively compact.

Optional Equipment

The line can be combined with additional equipment according to production requirements, including:

• Hydraulic decoiler

• Coil loading trolley

• Automatic feeding system

• Pre-cutting device

• Servo tracking cutting

• Finished sheet receiving table

• Automatic stacking system

Different automation options allow customers to configure the line according to their production volume, workshop layout and investment plan.

Customized Roofing Profile Solution

ZTRFM provides customized roll forming solutions based on customer drawings.

AG Panel and PBR Panel dimensions can vary between markets, manufacturers and construction standards. Customers can send us detailed profile drawings, and our technical team can design the corresponding roller system and production line.

Customization can cover profile dimensions, material requirements, feeding width, forming structure, cutting method, control system, decoiler and other auxiliary equipment.

Factory Testing and Quality Control

Before delivery, the production line can be assembled and tested at our factory.

Trial production is used to check feeding alignment, roller forming, machine operation, cutting performance and finished profile quality. The produced roofing sheet is compared with the confirmed drawing before shipment.

When necessary, customers can provide their own coil material for testing to make sure the machine is adjusted according to their actual production material.

After-Sales Support

ZTRFM provides technical support for machine installation, commissioning, operation and maintenance.

Customers can receive operating instructions, electrical documentation and remote technical assistance. Engineer installation and commissioning services can also be arranged according to project requirements.

If you are planning to produce AG Panel and PBR/R Panel roofing sheets, send us your profile drawings and production requirements. Our technical team can design a suitable double-layer roll forming solution for your factory.

Keywords:
AG panel roll forming machine,PBR panel roll forming machine,double layer roofing machine,R panel forming machine,metal roof panel machine