Samco Roll Forming Blog

It has been said that there is a fine balance between art and science when it comes to metal forming lubrication.  Subtle variations can occur during the forming process, die design and work piece metallurgy.  All of these factors are critical and can greatly affect product performance.  We are all aware of the benefits that come with selecting the right lubricant: it increases product life and ensures successful product output.  However, it is also essential to understand that by practicing proper lube methods and applications for your business, you can optimize benefits in parts storage, cleaning, general housekeeping and even waste disposal costs and procedures. Lubrication provides an essential barrier between the roll dies and the product surface. It helps to preserve the life of the machine   and reduce tool wear while allowing the work piece to move along faster and efficiently.

Whether you are using straight, water-soluble, synthetic and/or dry film oils, it is important to remember to only apply the lube where it is needed, when it is needed and solely in the amount it is required for.  There are a number of application methods used but generally speaking, many manufacturers use more lube than is actually necessary.  It is recommended that you should always decide first on what the optimum lube level for the job should be.  From there, you can determine the best application system to maintain the desired lubricant levels.  By applying precise lubricant levels to your process, you not only save in fluid costs but reduce clean-up on the factory floors, simplify part cleaning procedures, reduce paint blisters and lower environmental costs. Ideally, a system that incorporates low-volume and low-pressure technology aims to achieve optimum and efficient lubricant levels.

Always ensure that lube waste disposal meets all regulatory requirements especially if it enhances the roll forming process and reduces overall disposal costs.  Remember, it is the manufacturer’s responsibility to ensure that proper waste removal guidelines are adhered to.  Always remember the safety of your employees and the social responsibility of your organization.  If your lube supplier says it is okay for lube to be dumped down the drain, remember the manufacturer bears the liability – buyer beware.  ISO 14001 in your facility will also want to get involved with your company’s lube use, storage and disposal.  Keep track of your lube procedures and avoid over application – proper monitoring will ensure all safety and quality requirements are being met.   By understanding the environmental effects of your current lubricant and compatibility, you can audit your baseline environmental status and look to the many ways of outlining an improvement strategy when needed.

Managing your lubrication procedures, overall housekeeping, and keeping a regular log of lubricant levels are significant ways of cost reduction and overall savings for your organization.  By doing so, you are helping to protect the environment for people, products and machinery.  What are your company’s best practices regarding lube methodologies?

Share your story with us by visiting www.samco-machinery.com.

The future of building and residential development is growing favorably for metal. Thinking outside of the conventional wood and lumber box allows consumers to see the beauty, not to mention the long term durability and greening capabilities that metal has to offer. Whether replacing an old roof or adding an extension to your home, metal paneling and roofing complements any building project. You can install corrugated panels vertically or horizontally to adapt to the exterior/interior design of your home. It even comes in a variety of finishes and colours to suit your individual taste. Equipped with weather protecting benefits and long term durability, metal can survive high winds and seals out water. Metal keeps homes cool during the summer months and keeps warmth in during the winter. Resistant to fire, mildew, insects, and rot enables metal dwellings to outlast a life time. Cost-effective, green and good looks makes metal a premium home building material of choice.

We are seeing more of a trend in building and residential designs utilizing metal.  Widely used in many commercial and industrial properties, steel homes are also becoming increasingly popular.  Roof and wall panel roll formers allow construction manufacturers to successfully meet market demands in this expanding market.  Quick tooling change over’s enable building and construction suppliers to feature a range of profiles and designs.  This provides the end customer with endless options to complement any building project.  With this kind of versatility, architects and builders know that metal is logical, cost-effective and relates to many benefits allowing customers to think outside of the “conventional” wood and lumber box.  Whether you are considering to replace your old roof or perhaps adding an extension to your home, metal paneling and/or roofing is a comprehensive option from start to finish. What makes metal more attractive, is its price point from a long term perspective and its green capabilities. Because of its durability and recyclability, metal can be green as well as aesthetic.  There are a variety of finishes available even though finish is not often necessary.  These qualities are what draw design architects and builders to metal.  

When properly installed, the life expectancy of a metal roof or dwelling can last a lifetime, completely sealing out water, surviving high winds, and with weather protecting benefits like easily shedding snow during the winter. Metal is resistant to fire, mildew, insects, and rot. The corrugated panels can be installed vertically and horizontally to add a varied texture adapting to the exterior or interior of the home.  Metal roofing is great for cold and warm climates making homes more efficient, low maintenance and overall environmentally friendly.

Let us know your thoughts on ways to increase building efficiencies and green ideas by contacting Samco today.  You can also visit our roof and wall roll former product line for further information.

Do you have a product made of High Strength Steel?  Over the past 30 years, SAMCO has built some of the most innovative rollforming lines — handling products from 90,000 psi up to 220,000 psi yield strength Martinsitic coil stock — including in-line cold reductions performed during the rollforming operation.

The automotive industry is continually adopting higher strength materials so that thinner gauges can be used in order to reduce vehicle weight.

SAMCO also produces steel truss lines that rollform ¼” thick product made of 90,000 psi yield strength steel — and produces each component at over 325 feet per minute. 

Specially-designed auto-gauging control with digital readouts allow the operator to change from 0.090” to 0.210” thick material — in about 10 seconds — at the touch of a button. Automation built for the 21st century — SAMCO’s customers enjoy tomorrow’s technology today.

State-of-the-Art high speed Hydraulic Hydrex presses easily cut through this high strength steel — and can be powered by OPEN loop or digitially-controlled CLOSED loop servo accelerators.  These powerful hydraulically-powered presses can perform 200 strokes per minute — depending upon the application.

SAMCO offers flexible rollforming systems in fixed shaft and through-shaft duplex rollforming mills for High Strength steel applications.
 

Contact a specialist today to find out how to form high strength steel.

Samco Machinery world leader of roll forming machines was again showcased on Business News Network (BNN). President and COO, Bob Repovs was featured during an episode of Squeeze Play on May 6, 2009.

By Jeff K. Carson

When your company is seeking to purchase a rollforming line, there are two very distinct types of rollforming equipment in the market today. There is the type which is designed for lightweight, mobile use, at the work site (which we will refer to as “WORK SITE” equipment); and the type which is in-house, heavy duty, bolted-to-a-concrete-floor, non-portable (which we will refer to as “IN-PLANT” equipment).

Since both types of rollforming line have their place in the market — which one is right for your company? Here are a few points to consider in making that decision.

ANNUAL VOLUME:

One of the key indicators for determining the type of rollforming line you should be buying is found in the annual lineal footage of product you require. For example, if you are a contractor and need 92,000 lineal feet of a product per year, then you should probably be looking at the WORK SITE equipment line for the maximum value – even if it is installed in a factory. The cost ratio of capital equipment to the number of lineal feet dictates that the purchase price of the equipment be at a very low cost level. – otherwise, each foot of rollformed product might end up costing you $2,000 per foot for example.  And if your annual volume is 92,000 lineal per 8-hour shift, then you will need a high speed IN-PLANT line that can run 300-500 fpm.

MAXIMUM PRODUCT LENGTH:

The length of your product can also be a determining factor. Many architectural products today are designed to be seamless and of one continuous piece rather than assembled end-to-end in segments. This can reduce the risk of warranty and liability claims around problems such as leakage, etc. If your company will be involved in making seamless eavestrough, seamless roof panels, etc. —  in lengths of 80-120 foot spans, then your decision is clear;  you ought to be considering the WORK SITE equipment.  Although IN-PLANT lines could theoretically produce equally long segments of product, generally it is the maximum length of the truckload at 55-57 feet that restricts the length of product rollformed in the factory.

LINE SPEED:

Many products today are pushing the manufacturing limits to new heights in the line speeds in which they operate. Cornerbead lines or steel stud and track lines can operate at speeds in excess of 500 fpm. If your goal is to have a high speed line for your company, then you can probably expect to bolt your IN-PLANT equipment to the concrete floor to attain those production rates. Most WORK SITE rollforming lines operate less than 50 fpm as they were not designed for this type of application.

 
COIL SIZE AND COST:

Another important item to consider as you plan your equipment needs is the size of the coil and its cost.  Most IN-PLANT rollforming lines will provide an industrial level uncoiler which can hold a standard coil weighing in a 4,000-lbs, or 6,000-lbs – depending on the product – with a coil Inside Diameter of 20-inches and an Outside Diameter of 60-inches or 72-inches. And the company which sells you the coil will have a standard price per lb for this material (i.e. $0.40/lb). Most WORK SITE rollforming lines cannot support these type of coil weights or sizes; and many customers are shocked to find that the small “pup” coil (1,000-3,000-lbs) which must travel to the site ends up costing 40-80% more (i.e. $0.69/lb) for material because of the surcharge that many steel service centers will apply for their additional labor of creating these smaller coils.

One reason that most popular roofing panels are rollforming IN-PLANT is due in part to the 42” or 48” wide strip width. So it is not very common to find a large panel such as an R-Panel rollforming line at the WORK SITE.  The coils are generally too large to handle. Some products such as guardrail might seem ideal to manufacture at the WORK SITE until you consider the massive size of the roll tooling and large stands and shaft diameters necessary to manufacture such a high strength product; and so the thickness of the material also helps determine the decision to rollform IN-PLANT.

So do your homework. Evaluate the needs of your company with an eye to the future of where you want to grow your business. Consider the speeds, the volumes, the liabilities and the costs. And select the right equipment for the right job.

JEFF K. CARSON
International Sales Manager
SAMCO MACHINERY LTD
www.samco-machinery.com
jcarson@samco-machinery.com
 

Steel framing is becoming a much more popluar choice for commercial, industrial and residential construction. Steel studs are much stronger than wood because they can withstand all elements that different climates face. Elements such as termites and fires, just to name a few.

We get many calls from companies looking to rollform steel stud and track. Many times these people don’t know where to get started. The education we give them is what the most popular sizes are and the difference between structural and drywall stud. We now have a page for those looking to rollform stud and track that will explain the differences between the the load bearing and non load bearing.

Samco’s new 20,000 square foot rollform manufacturing facility in Tatarpur near Faridabad has 2 CNC machines and a boring mill. Our new CEO Vivek Singh who joined March 3, 2008 will take the key leadership role and steer Samco India to its intended path. That path is to bring the 35 years of rollforming experience to India to compete with Korea, Taiwan and China.

Samco India has already received a few jobs in the automotive industry including a rollformer for TATA…the NANO, (PEOPLE’S CAR). TATA motors is the largest OEM in India. Samco India is providing a complete roll forming system to make 6 major chassis parts. This rollforming production system includes 10,000 lb. double uncoiler, a 50 ton pre punch press, a 30 ton flying cut off press, a 18 pass rollformer, 5 stretch benders, two 130 ton mechanical presses, 2 multiple punching presses and 2 flange notching presses.

Many manufacturers of steel studs, purlins, roof trusses make more than one product on the same roll former. In many facilities, an entire day can be spent changing each roll on the rollformer getting ready for another product. In the stud industry where the speed of a rollformer is critical (rollformers run at over 500 fpm) because the volumes are so high, this downtime causes a huge ineffiency.

Samco has a duplex rollformer for these customers. The width of the web or flange for example can be changed at literally the touch of a button. On our purlin rollformers for example, even changing from a CEE to a ZEE purlin can be done in 7 seconds at the touch of a button! The stud and track industry cannot afford to have this downtime with the increasing demand for their products. All the stud manufacturers are using duplex rollformers.

For more roll former news and articles on inovations in the rollforming industry visit Industrial Machinery News (http://www.industrial-machinery-news.com)

Making rollformers for customers that require customization can be costly. To make it less costly for us, Samco invested in software that would enable us to tryout the material in the rolls on the computer. What many rollform equipment manufacturers do is test the material on new products on the shop floor. If the part doesn’t come out right, often the rolls need to be regrinded. And if the part is very difficult, how many times can the roll tooling be regrinded before they actually need to be remade?

The software we use for our roll tooling on our rollform equipment is called COPRA FEA. It was desined by DATA M in Germany. Samco is the only rollforming equipment manufacturer in North America that is using it to it’s full potential. We will have customers come to us with a part they are thinking about roll forming. We can put it through this software and recommend changes be made to the part to make it less costly to rollform with less passes.