Roll forming machine of Knauf structure

As you know, one of the most important developments in the construction industry took place with the invention of Knauf, so that the major benefits of this material caused it to quickly replace traditional materials.
Features such as speed and ease of installation, access to facilities, earthquake resistance, thermal insulation and etc, caused Knauf to greatly affect construction speed and energy crisis.
The proliferation of Knauf products today is certainly the result of years of increasing effort by experts in the field. Knauf products consist of two main parts:

 

Part I) Metal equipment

These products are made of metal and include substructure equipment such as F47, U36, L25 (L section), Stud (section C) and runner (section U) and fittings such as clips, brackets as well as decorative structures such as T60, T120 and T360.

Image 1 : Sections and profiles of Knauf infrastructure   

Part II) Gypsum Board sheets

Another part of which Knauf structures are mainly composed includes gypsum-based products such as gypsum Boards, tiles and gypsum panels.
Pooya Boresh Machinery of Arak is proud to have been useful and constructive in all fields leading to the product in the Knauf sector. In addition to designing and manufacturing custom roll forming machines in the field of Knauf substructure manufacturing equipment, this group is also designing and manufacturing roll forming machines for producing sheet and tile profiles.

Knauf Structure Roll Forming Machine

Image 2 : sample of construction of roll forming machine of Knauf

Gates, blocks and shafts of type A are used in the construction of roll forming machine of Knauf. The Type A gates of a dynamic cutting set are able to cover rollers with a maximum diameter of 220 mm.
Type A bearing blocks are capable of supporting bearings with an outer diameter of up to 90 mm. Shafts can drive rollers with an inner diameter of 50 mm.

Image3 : sample of construction of roll forming machine of Knauf

The maximum sheet thickness in type A shafts is equal to 1 mm and the maximum sheet inlet width is 140 mm.
The process of making shafts in the official standard of Pooya Boresh Arak Company is still common and in the form of the following process:
A: Choosing the right raw materials
B: Precise and controlled turning with CNC machine
C: Suitable hardening with induction method (induction)
D: Precision mobile grinding with micron precision
Knauf structure machines of Pooya Boresh Arak Company are made in two types of with gearboxes and chains mechanism.

Gearbox roll forming machines are undoubtedly better in terms of performance and adjustability, but due to the high initial cost of construction, they are usually not economically justified for light structures. Therefore, most of the structure devices are made by chain mechanism. At the request of the customer, the device is made with a gearbox mechanism.
The bodies of the machines are machined very precisely after annealing. The selection of materials, manufacturing and machining of the device gates and other components is also done according to international manufacturing standards.
Observance of the highest production and quality standards in the manufacture of devices in this collection has led to the production of devices with the power of quantitative and qualitative competition in today’s market. It also causes the machines made by Pooya Boresh Arak to have an annual added value, and after working, they can be traded and bought in a valuable way without dropping the price.

Image 4: construction of roll forming machine of Knauf

Technical specifications of various types of Knauf structure roll forming machines

Knauf F47 roll forming machine

Image 5 : Knauf Structure Roll Forming Machine

• Number of stations 15
• Type of gate: A
• Type of block: A
• Shaft diameter: 43 mm hardened
• Hydraulic cutting system with pressure 75 bar
• Type of guillotine incision in motion (continuous)
• Cutting speed 30 mm per second
• Machine weight 3000 kg
• Roll forming length 7 m
• Roll forming width 530 mm
• Roll forming height 1220 mm
• Production line length 15 meters
• 9kw power consumption
• 3-phase electricity

Knauf U36 roll forming machine

Image 6: Knauf Structure Roll Forming Machine

• Number of stations 8

• Type of gate: A

• Type of block: A

• Shaft diameter 43 mm hardened

• Hydraulic cutting system with a maximum pressure of 175bar

• Type of moving guillotine incision (continuous)

• Cutting speed 30 mm per second

• Roll forming weight 2500 kg

• Roll forming length 4.5 m

• Roll forming width 500 mm

• Roll forming height 1220 mm

• Production line length 12 meters

• Power consumption 6kw

• 3-phase electricity

Knauf L25 roll forming machine

Image 7: Knauf Structure Roll Forming Machine

 

• Number of stations 9

• Type of gate: A

• Type of block: A

• Shaft diameter 43 mm hardened

• Hydraulic cutting system with a maximum pressure of 175bar

• Type of moving guillotine incision (continuous)

• Cutting speed 40 mm per second

• The weight of the device is 2650 kg

• Roll forming length 5 meters

• Roll forming width 500 mm

• Roll forming height 1220 mm

• Production line length 13 meters

• Power consumption 6kw

• 3-phase electricity

Profiles of click structures (lattice or tile structure)

Shield profiles (T-shaped sections) T60, T120 and T360 are used for the construction and installation of lattice structures. These profiles are mainly made of galvanized or aluminum materials because they must have sufficient strength and light weight and must be moisture resistant.

The quality and method of production of these Profiles is very important and affects the insulation properties, strength and ease of installation, moisture resistance and other properties of these structures.

Image 8: Sample of Shield profiles

The specialists of Pooya Boresh Arak Company, in collaboration with experienced university professors and continuous and tireless research, have succeeded in producing and localizing these roll forming machines, with a quality that is competitive with similar European products.

Roll forming machine of T60, T120 and T360 Shield profiles

• Number of stations 16
• Type of gate: A
• Type of block: A
• Shaft diameter 43 mm hardened
• Hydraulic cutting system with a maximum pressure of 175bar
• Type of moving guillotine incision (continuous)
• Cutting speed 35 mm per second
• The weight of the device is 3800 kg of chain and 6000 kg of gearbox
• The length of the forming roll is 8 meters
• Chain roll forming width 500 mm
• Gearbox roll forming width 1200 mm
• Height of roll forming chain and gearbox 1200 mm
• Production line length 18 meters
• Energy consumption kw 10
• 3-phase electricity

Price of Knauf L25, U36, F47 structural machines

The price of Knauf structure construction devices varies based on the speed and length of the device and the number of gates. Also, the main feature of the device is very impressive in terms of structure.

Prices and signs of poor or low quality devices

If the body of the device is made of iron sheet and is welded on the chassis, the value of each device is a maximum of 35 million Tomans and the F47 device is a maximum of 45 million Tomans, but the device with this characteristic is very poor in terms of quality and technology. Ultimately, in this competitive market, it is not economical at all.

Prices and signs of medium devices

Also, if the body of the device is made of sheet metal and the gates are cast iron or steel, the value of the L25 and U36 devices is a maximum of 50 to 60 million Tomans and the maximum price of the F47 device is equivalent to 70 million Tomans. In this example, the risk of production error is very high and usually the duration of the settings and failure of the device is very important.

Characteristics of standard and quality devices

1- The shafts of the device are completely hardened and grinded and the manufacturing standards are observed in it so that all the shafts of the device (of course similar shafts) can be replaced with another one and so-called break.
2- The body of the machine is made integrated and after complete annealing, machined precisely.
3- The setting conditions of the device should be designed in such a way that it is very comfortable and understandable for the operator and imposes the least amount of waste on the manufacturer.
4- Quality of standard parts such as sprockets, bearings, electrical appliances, etc are the main influential component in the price is acceptable and its standard parts are selected from common and abundant codes in the Iranian market.
5- Machined gates should be made of ductile iron or in special cases of CK45 steel and quite similar, and the gates must be calibrated.
6- Supply of parts and support of the manufacturer is acceptable from two perspectives of training and supply of spare parts of the device.

Note: Roll forming machine without technical services, parts supply, continuous training and support by the manufacturer is just a pile of scrap metal.

Prices and specifications of Chinese, Turkish and European devices:

No quality European device can be found that fits the criteria of a good device and is not at least 4 to 5 times more expensive than domestically made devices (about 35 to 70 thousand dollars). The average Chinese machine is not less than Iranian machines. Reduces transportation and customs issues, the unavailability of parts and training, and the core value of the device.

Price of Knauf construction and structure machines of Pooya Brash Arak Company

• Pooya Boresh Arak Company has tried, by observing all the technical standards of standard machines in its products, continuous customer support as well as quality in the size of European samples, the possibility of access to quality machines and machines at a much lower price than the samples. Europe for all valuable industrialists.
• The price of U36-L25 device made by Pooya Boresh Arak Company, depending on the type and brand of electrical appliances, bearings and drive system of the device, is in the range of 90 to 130 million Tomans.
• The price of the F47 device of Pooya Boresh Arak Company is from 110 to 150 million Tomans, depending on the type and brand of electrical appliances, bearings and drive system of the device. .

• These prices are adjusted to the current conditions of the country’s dollar and metals market.