Profile Information
Heavy-duty rack uprights support pallet racking systems, featuring perforated C or box profiles. Widely used in the US, Europe, and industrial logistics sectors.
Typically produced from 1.5–3.0mm cold-rolled or galvanized steel, ensuring high load capacity, structural rigidity, and durability for demanding warehouse applications.
Typical Applications
| Heavy-duty pallet racking systems | Automated storage and retrieval systems (as/rs) |
| Distribution centers and logistics hubs | High-density storage systems |
Profile Specification
| Profile | Heavy-duty rack upright | ||
| Common Material | Galvanized steel/hot-rolled steel | ||
| Yield Strength | 235–550 MPa (customizable) | ||
| Thickness | 1.5-2.5mm | ||
| Profile Features | Various Hole Shapes And Slot Patterns | ||
| Tall, Narrow Profile With Multiple Bends | |||
| Regularly Spaced Slots For Adjustable Beam Connections | |||
Production Line
High-efficiency roll forming line for heavy-duty rack uprights, delivering precise punching, stable forming, and continuous cutting for industrial storage systems.
Flow Chart
Decoiler with leveler → Punch press → Guiding → Roll forming machine → Flying hydraulic cut → Out table
Factory Live Test Video 🎯
Prior to shipment, every Goalon roll forming machine undergoes strict trial testing. Below is the live footage of our heavy-duty box beam production line under continuous operational testing.
Why Choose This Roll Forming Production Line
✅ High-Precision Continuous Punching & Feeding
Servo feeder and dynamic punch press eliminate cumulative pitch errors, ensuring precise hole spacing for seamless warehouse rack assembly.
✅ Flying Cut Technology Maximizes Line Output
Follow-up hydraulic cutting system enables non-stop continuous roll forming, maintaining a high production speed of 20-25m/min without cycle pauses.
✅ Heavy-Duty Station Design for Thick Materials
Features 18 forming stands with GCr15 rollers (HRC58-62°) and 40Cr solid shafts, effortlessly processing 1.5–2.5mm structural steel plates.
Machine Details 🎯
Function Of Machines
Steel Coil Decoiler With Leveler
The integrated decoiler and leveling unit combines material feeding and flattening in one system, saving space and improving synchronization.
Compared to separated units, it reduces alignment errors and labor. It ensures stable strip feeding, especially critical for thick materials. Optional hydraulic expansion, pressing arm, and higher-capacity configurations are available.
♦ Punch Press & Looping Pit
The servo feeder ensures accurate strip positioning into the punch press, minimizing cumulative errors. The punch press performs high-speed hole punching with consistent precision, critical for rack assembly compatibility.
It supports custom dies for various hole patterns. Higher-tonnage presses or multi-station punching solutions are available depending on production demands.
♦ Roll Forming Machine
The roll forming machine is the core unit for shaping IBR roof panels, using multiple forming stations to gradually form the trapezoidal profile.
It ensures precise dimensions, smooth surface finish, stable operation, and consistent panel quality, making it suitable for continuous, high-efficiency production.
♦ Cutting Device
The flying hydraulic cutting system enables continuous production without stopping the roll forming process. The cutting unit synchronizes with profile speed, achieving precise length control without deformation.
This high-end configuration improves efficiency. Standard stop-cut solutions are also available for lower budget requirements.
PLC Control Cabinet & Encoder
In a cold roll forming line, the encoder works with the PLC to provide real-time feedback on material position and speed, ensuring precise feed, synchronized forming, and accurate length control for cutting and punching.
Production speed, product length, and quantity can be set on the control cabinet. The display language can be customized according to customer requirements.
Machine Photos
Optional Upgrade —— Punch Line
For the production of heavy-duty rack upright profiles, we recommend separating the punching and roll forming processes into two independent lines.
This setup improves production efficiency and process flexibility while reducing downtime, allowing each line to be optimized independently for stable and consistent production.
Specifications Of This Roll Forming Production Line
| Component | Specification | Details |
| Decoiler | Type | Hydraulic |
| Capacity | 5T | |
| Leveler | Type | 3 upper+4 lower shaft rollers |
| Roll forming machine | Size changeover | Automatic |
| Power | 7.5Kw | |
| Structure | Cast-iron stand | |
| Driving system | Chain | |
| Machine base | 350x6mm H steel | |
| Station number | 18 main stands | |
| Forming speed | 15-20m/min | |
| Roller material | GCr15 steel rollers with CNC machining, heat treatment, precision finishing, polishing, and chrome plating, achieving HRC 58–60 hardness. | |
| Shaft material | 45# steel shafts with CNC machining, quenching and tempering, precision finishing, polishing, and chrome plating | |
| Welder | Type | Laser |
| Operation Mode | Forming machine keeps running when welding | |
| Cutting | Type | Saw |
| Operation Mode | Forming machine keeps running when cutting | |
| PLC control cabinet | PLC | SIEMENS |
| HMI touch screen | MCGS/SIEMENS/Schneider | |
| Encoder | OMRON | |
| Production line | Total power | 11-18kw |
| Speed | 15-18m/min | |
| Dimension | LWH 10×1.4×1.6m | |
| Weight | 6-10T |
This production line features a heavy-duty 350x6mm H-steel base structure and GCr15 CNC-machined rollers (HRC 58–60), ensuring maximum structural stability and zero precision loss over millions of cycles. With integrated Siemens PLC and Omron encoders, operators achieve real-time speed monitoring and sub-millimeter length cutting control.
Customizable Rack Upright Forming Solutions
We customize the line based on upright profile design, hole patterns, thickness range, and load requirements, ensuring compatibility with different racking systems and standards.
Ideal for racking manufacturers producing heavy-duty warehouse systems requiring high strength, precise hole alignment, and stable mass production of thick steel uprights.
| Material | Thickness | Production speed | Automation level |
| Perforation | Embossing | Cutting | Machine color |
| One machine for multiple profile sizes | …… | ||
Comprehensive Services & Support
Safety Designs
Optional safety covers are available to protect operators from moving components while improving workplace safety and compliance.
Warranty
2-year warranty with lifetime technical support and after-sales service.
Professional Packing
Machines are packed in plastic film and labeled for easy identification and assembly, and secured inside the container with steel cables.
Installation Guide
Besides paid on-site installation and training services, we provide installation and operation manuals, along with operation videos before shipment for guidance.
Roll Forming Machines Delivered Worldwide
From our factory to customers across the globe.
Our roll forming machines have been successfully delivered to customers across multiple countries and industries, including construction, storage systems, solar mounting, and steel fabrication.
Each project reflects our engineering expertise, manufacturing capability, and commitment to providing reliable metal forming solutions for long-term customer success.
Frequently Asked Question
The standard configuration operates at 15–20 m/min. Higher-end configurations can reach 30–40 m/min, and even higher speeds can be customized according to specific production requirements.
Lead times range from 30-50 days post-order, varying by customization level and supplier location. We typically require 45 days for standard machines.
Not always. Flying cut improves efficiency and output. Stop-cut is a more economical option depending on production speed requirements.
Yes. We are a professional manufacturer that produces both standard market profiles and customized profiles. We can also sign an agreement to ensure that your drawing will not be shared with other parties.
There is no need to worry. Our machines are designed for easy installation and operation.
Before shipment, we will finish the main assembly and testing in our factory. When the machine arrives, you only need to place it in position, connect the power supply, and it can start working.
We will also provide:
detailed installation and operation manuals
machine layout drawings
wiring diagrams
online technical support (video call / photos / videos)
If needed, we can also arrange an engineer to come to your factory to help with installation and training. Many of our customers complete installation smoothly with our online guidance.
30% deposit is paid before production, the balance paid after inspection confrmation, before shipment.
