As the metal roofing industry continues to grow, the demand for high-quality panels is increasing. While standing seam roofs remain the most popular, there is a rising trend in metal siding. Popular profiles like board-and-batten combined with contemporary finishes like rustic woodgrain and customized designs have galvanized the industry. Additionally, metal is clean, durable, and maintains its appearance over time.
To meet the growing demand, manufacturers rely on rollforming machines for fabricating metal panels used in roofing and siding. Whether the panels are made in-plant, prefabricated, or produced on-site using portable machines, rollformers are the backbone of the industry.
When it comes to metal panel forming machines, there are two types: in-plant and portable. This is not a strict delineation as some in-plant machines can be placed on a trailer, while many manufacturers use portable rollformers in-plant. Despite this crossover, it is more common to see a portable rollformer used in-house, as in-plant rollformers can weigh several tons.
This article explores the differences between large in-plant rollforming machines and portable rollformers, covering the advantages and limitations.
The rollforming process
As a process, rollforming is straightforward. Metal coils, usually finished steel, aluminum, or copper, are fed through a series of forming rollers that gradually bend the material into a desired shape. These machines can form roofing and siding panels with precision, creating strong, lightweight profiles that can be fastened with screws, nails, or clips—either exposed or hidden, depending on the type of panel.
Key steps in the rollforming process include:
Material feeding
Metal coils, typically steel, aluminum, or copper, are loaded into the machine. In-plant machines handle larger coils than portable machines, but portable
rollformers can still carry several thousand pounds of metal on multiple reels.
Incremental shaping
The metal passes through a sequence of rollers that apply small, precise bends, gradually shaping the metal into the desired profile.
Cutting and punching
Once the profile is formed, the panels are cut to the required length, and optional punching features can add holes for fasteners. In-plant machines often have integrated notching or punching mechanisms, while some portable models also offer notching as an additional feature.
Automation
Most modern rollformers integrate automation for panel cutting and profile adjustments. This reduces manual labor and increases precision, with more advanced machines offering computer controllers to manage specifications, upload job specs, and troubleshoot issues. The result is durable metal
panels, perfect for roofing, siding, and even structural components.
Portable rollforming machines
These machines have become popular over the years due to their flexibility. Portable rollformers allow panels to be produced at the job site, cutting out transportation costs and reducing the risk of panel damage during transit. By producing panels onsite, contractors can respond to changes in
demand, adjust panel sizes, and have full control over the manufacturing process from start to finish.
Not only do portable rollformers eliminate transportation costs, but panel damage can result from loading and unloading panels. Avoiding these panel damages translates to significant savings.
Portable rollformers also allow contractors to produce panels exactly when needed, reducing the risk of errors in panel size and quantity. This is particularly useful for projects requiring unique or non-standard panel lengths. When using prefabricated panels, there is always the risk that the panel could be short by an inch or so. Once the shipment is received, it is too late to fix that mistake, but not so when panels are run onsite.
Another advantage of portable machines is that they can produce panels of any length. In contrast to prefabricated panels, which are limited by truck bed sizes, portable rollformers can generate any length of panels, and with the right equipment, run them out right on the roof, which is especially useful for large industrial structures.
Finally, portable rollformers can be used both on-site and in-plant, giving manufacturers and contractors the flexibility to switch between job sites and in-house production, depending on their needs. They are the go-anywhere, do-anything option.
However, there are some drawbacks to portable machines. While some portable rollformers can produce panels at speeds of up to 46 m (150 ft) per minute, most max out at around 23 m (75 ft) per minute. Gas engines typically run faster than electric motors, so performance can vary even with one machine.
Also, to avoid gas fumes in the facility, either a generator or a dual gas-electric power source may be needed.
Another thing to keep in mind is portable machines are not built for continuous, highvolume use like in-plant machines. For eight or 10 hours of constant production per day, an in-plant rollformer is sturdier and faster for that kind of workload.
Lastly, while portable machines offer a variety of panel profiles, they may not support specialty architectural profiles that require customized tooling.
In-plant rollforming machines
In-plant rollforming machines are designed for high-volume production. These large, stationary machines, weighing upwards of 6,804 kg (15,000 lbs) are perfect for manufacturers producing metal roofing panels in bulk. They are faster, more automated, and better equipped to handle large-scale production demands compared to portable models. In-plant machines can produce panels at speeds between 46 and 92 kg (150 and 300 ft) per minute, significantly faster than portable rollformers. Another advantage is that in-plant machines can produce custom architectural panels. Whereas portable rollforming companies manufacture stock profiles, some in-plant companies can also engineer specialized profiles.
Unlike portable rollformers, these hefty machines are designed for non-stop use, making them ideal for bulk production.
Despite these benefits, in-plant rollformers have some notable limitations, with cost being a major difference. In-plant machines generally start at around $400,000, and with custom options and additional profiles, prices can easily exceed $1 million.
Another issue is having adequate room to run these machines and accommodate run-out tables and other equipment. Inplant machines are stationary and require significant space in a manufacturing facility.
Choosing between in-plant and portable rollformers. For small to medium-sized contractors, portable rollformers offer flexibility, customization, and cost savings by eliminating the need to transport panels. These machines are easy to transport, making them especially useful for contractors working in remote locations or performing chop-and-drops at various locations.
In contrast, in-plant rollformers are more suited to large-scale production. These machines deliver high-speed output, full automation, and the ability to produce custom profiles. These machines are best for companies needing to produce panels in bulk to meet heavy market demand.
Choosing between an in-plant or portable rollforming machine comes down to the business size, production needs, and budget.
Rick Zand has worked as a freelance writer, college professor, and university director of admissions. He’s currently the content specialist for marketing at New Tech Machinery, a manufacturer of portable rollforming machines. He resides in Denver, Colo.