The production of corrugated board is a very attractive business idea - the only question is the equipment. Building materials are getting more expensive every month. They are always in demand especially, such as corrugated board. It is used on any construction site as:
- facing material;
- frame for pre-fabricated non-residential facilities (for garages, warehouses, hangars, amenity premises);
- territory fencing;
- roofing material;
- fixed formwork for monolithic construction of buildings;
- material for auxiliary, decorative design (visors, canopies, valleys, skates, ebbs, siding and complex products).
The machine is equipped with structures that allow the production of high quality corrugated board
Manual sheet bending machine is an inexpensive, compact and versatile equipment for the production of corrugated board. In terms of production quality, it is in no way inferior to factories. The low cost is primarily due to low productivity. Manual labor always famous for high quality and low performance. The structures of beams and supporting elements are made of high strong metals. This allows for a long service life, working with metal sheets up to 1.5 mm thick. The cam clamping mechanism allows you to work with the machine with one hand, without violating the geometry of the workpiece. The equipment allows you to work with rolls of galvanized metal sheets without pre-cutting. The set of equipment includes a steel, roller knife made of durable metal alloys. It allows you to cut products yourself. The length of the sheet can be changed at the request of the customer. The principle of operation of the machine is quite simple. A strong steel beam bends a wave of the required shape with a control force. The force and shape are pre-adjusted to the thickness of the workpiece sheet. The control is carried out by sensors, which at the right time stop the process of metal bending. The machine operator must pre-configure all equipment controls before the production of corrugated board. A special scale controls the course of the traverse and the angle of the bend shape. The process is carried out cyclically until the completion of the production of the profile sheet. Profile bending manual equipment allows two workers to produce about 120 sheets of corrugated board in size - (1100mm X 2500mm) in one shift. In production, the machine for self made will never leave scratches on the polyester coating of the sheet. The next benefit of working on such a machine is the lack of power supply for its operation.
The professional flooring is irreplaceable on any building production
Decking for Lately gained high popularity among building materials. And in certain nodes of the construction project, it has become an indispensable material. Important information about corrugated board. It has acquired several types in different fields of application:
- roofing;
- carrier;
- wall;
- facing;
- sandwich panels (wall and facing corrugated board in a pair, and between them a heat-insulating layer of foam or polyurethane).
- durability throughout the operation;
- mechanical strength;
- little weight;
- simplicity in installation work;
- relatively low cost;
- aesthetic appearance.
Is it possible to make corrugated board (corrugated board) by ourselves from almost any sheet metal according to its sheet size, step and wave height in your country house?
After all, automated machines cost from 2 million rubles, and manual from 70-100 thousand rubles.
There is a way out! A manual machine for mini-production of individual products!
The cost of the sample does not exceed 2 tr.
Machine weight 40 kg. Transported in a car.
Overall dimensions - 1300 mm × 900 mm × 350 mm
Sheets for forming can also be transported on a roll without using a truck.
The machine can be made by a low-level welder in 1 day + adjustment.
The possibility of reprofiling the machine to "false bend"
Used materials and accessories.
Carriage:
1 Bearing - Inner diameter 40 mm, outer 80 mm, rim width 15-20 mm (approx. z 208 semi-closed to facilitate lubrication) - 4 pcs. thereby increased the wave width). Forming bearings need to be fixed eccentrically (welding is fast and affordable, but requires accuracy and experience) or mounted on a shaft made by a turner, or other options)
2 Pipe 1" - 1 meter (handle), 25 cm (upper shaft) and 15 cm (lower shaft).
3 Guide plate.
Bed 1350mm; (for sheet width 1250 mm.)
I recommend making a machine for a popular sheet size (1m x 2m)
1 Corner "32" , 1200 mm - 4 pcs. (for the upper guides of the carriage)
2 Corner "25", 1200 mm - 2 pcs. (for molding guides at the bottom of the machine)
3 Pipe 1" or "32" to form the "skeleton" of the frame - about 3 meters.
4 Corner "32" for the manufacture of a sheet feed guide and corrugated board exit at a right angle.
5 Rebar, strip or other linear products - about 3 meters.
6 Electrodes and your wish!
P.S. For greater liquidity of your micro-production, we recommend that you purchase sheets at factories or bases in rolls by weight.
By agreeing on a good discount or purchasing a product at a bargain price, you can count on a profit of 80-100%
Metal profiled sheet, without exaggeration, can be called the most versatile building material. Due to the high demand, its production, and, as a result, the manufacture and sale of machines for the production of corrugated board, is a very profitable business.
An example of a corrugated board machine with partial automation
There are two main types of equipment for the production of corrugated board - these are manual machines used to produce small volumes of corrugated board, and automatic and semi-automatic rolling mills, which produce metal profiled sheet on an industrial scale.
Manual machine for the production of corrugated board
Manual profiled sheet machine can do profiling sheet metal up to 2.5 m long and is an alternative to powerful industrial rolling mills in cases where you need to produce small batches of corrugated board.
For example, such a machine is almost indispensable in cases where it is necessary to mount roofing at remote sites. In these cases, the delivery of a metal profiled sheet to the site can often be much more expensive than the cost of its manufacture.
The manual profiled sheet machine is easy to maintain and is driven by human muscle power. Moreover, due to the leverage system, a lot of effort is not required.
A manual corrugated sheeting machine, which costs about $2,000, will pay for itself within two to three weeks, even if it only produces 50-100 corrugated sheets per day. Provided that the productivity of such machines can reach 300 m² of profiled sheet per day, and even more. As payback example such a solution, we will calculate the cost of a profiled sheet produced on such a machine.
Example
The average price of rolled thin-sheet galvanized steel is about 1300-1500 US dollars per ton. From this amount of metal it is possible, using manual machine for corrugated sheet, produce approximately 250 m² of profiled sheet in just one day. Knowing that the price of galvanized steel profiled sheet is about 8 USD per one square meter, we can calculate that the cost of 250 m² will be 2000 US dollars. Thus, in addition to the cost of the metal, buying such a quantity of finished corrugated board, you will pay approximately 600 US dollars for its manufacture.
Based on the given data and taking into account how much a corrugated sheeting machine costs, it is easy to calculate the payback period for this investment. As a rule, it is only a few weeks.
The advantages and disadvantages of manual machines for corrugated board include the following:
- small production area necessary to accommodate such equipment;
- easy reconfiguration the number of waves or profile trapeziums;
- high performance (two workers in one shift can produce up to 300 m² of corrugated board);
- does not require electricity;
- reliability and simplicity in maintenance and operation;
Many modifications of such equipment, such as, for example, a machine for the manufacture of profiled sheet SPR-2.1, manufactured in Ukraine, can produce products not only from galvanized metal, but also from sheet steel with a polymeric protective and decorative coating.
Many machine-building enterprises in Europe and the CIS countries manufacture machines for the production of profiled sheets, so it will not be difficult to buy a machine for profiled sheeting.
The machine for the production of corrugated sheet works as follows:
- with the help of manual or stationary electromechanical scissors, a workpiece of the required size is cut out of sheet steel;
- the prepared workpiece is inserted into the machine with its side;
- with the help of a special handle, guides are actuated, bending the entire length of the metal sheet to the required angle;
- having thus formed one side of the profile trapezoid, the workpiece moves on the desktop to form the next trapezoid, and so on;
- after that, the sheet of metal unfolds and the other side of all the trapeziums of the corrugated board is formed in the same sequence;
You can buy a machine for the manufacture of corrugated board in a variety of modifications. They differ in the amount of equipment. So, for example, some types of machines are equipped with interchangeable dies for the manufacture of various grades of corrugated board. The kit of a manual machine may also include a special roller knife for cutting a metal sheet. Depending on the configuration and manufacturer, the price of a profiled sheet machine may differ several times, so be careful and choose only those options that you really need.
Industrial machines for the production of corrugated board
It is often said that in the factory, the profiled sheet is manufactured on rolling mills. But it is more correct to call them corrugated board production lines, since the rolling mill or the profiled sheet machine is only part of them.
Such a line usually includes the following equipment:
- cantilever or two-bearing decoiler;
- circular knife for cutting off a steel billet from a roll;
- multi-stand rolling mill;
- guillotine shears for cutting profiled sheet;
- receiving device with a retractable trolley;
- automated system line control.
You can buy a machine for the manufacture of profiled sheets in a different configuration. Many manufacturers offer additional options interchangeable modules of rolling mills. Interchangeable modules allow you to quickly switch from one brand of profiled sheet to another, without wasting time on changing the rollers of the rolling mill.
The rolling mill is the key element of the corrugated board production line
You can also be offered a loader for mounting sheet steel coils on the decoiler and transporting the profiled sheet from the receiving device to the packaging area or finished product warehouse.
Installing an automation system on the production line allows you to create a high-performance machine for the manufacture of corrugated board, the price of which will be slightly higher than semi-automatic options, but productivity will increase significantly. Namely, the payback period and profitability of investments depend on productivity.
The productivity of the line for the production of corrugated board is determined by the speed of rolling. For modern automated lines, this characteristic can reach 40 m/min. In fact, the productivity of the line is somewhat less than the rolling speed. This is due to the fact that some time is needed to cut each sheet of finished products. Therefore, at a rolling speed of 40 m/min, the line capacity will be 32-34 m/min.
Automation panel on a machine for the production of profiled sheets
The table below shows the cost of production lines for the production of certain types of profiles.
| Name equipment |
Machine for production corrugated board, price in rub. VAT included |
| Automated complex for the production of corrugated board С25-1050 |
2 137 500 |
| Automated complex for the production of corrugated board С18-1100 |
1 710 000 |
| Automated complex for the production of corrugated board С10-1100 |
1 898 820 |
| Automated complex for the production of corrugated board C21-1000 |
2 057 220 |
| Automated complex for the production of corrugated board H114 |
3 727 500 |
| Automated complex for the production of corrugated board H75-750 |
3 135 000 |
| Automated complex for the production of corrugated board С44-950 |
3 195 800 |
| Automated complex for the production of corrugated board C7 |
1 463 000 |
| Automated complex for the production of corrugated board NS35-1000 |
2 350 300 |
| Automated complex for the production of corrugated board H60-845 |
2 369 300 |
Today, the leader among products from thin-sheet steel products is undoubtedly corrugated board. It is applied to the device of protections, fences, roofs and wall designs. Due to such popularity, the production of corrugated board has increased many times over. Let's look at some of the features that characterize the production of corrugated board and equipment for the production of corrugated board.
In the industry, it is known as profiled or corrugated sheet. The main function that equipment for the manufacture of corrugated board should perform is to give the metal a certain shape under mechanical pressure on the workpiece.
To put it simply, the machine for the manufacture of corrugated board makes a profile sheet from a smooth sheet.
Profiled sheeting machine
Distinguish between hot and cold industrial metal forming. Rolling machine for corrugated board operates at ambient temperature and does not require heating of the raw material, i.e. uses cold method processing of raw materials.
Lines and machines for the production of corrugated board perform 2 main operations: rolling and cutting. In production, the rolling operation is also called profiling, since the metal blank receives a profile shape.
Manufacturers produce corrugated board of various modifications. The scope of its application also depends on the type and type. For each model, depending on the height of the profile, which is characterized by corrugated board, the equipment for its production will develop a different pressure force.
Equipment for the production of corrugated board can be classified according to the degree of mechanization of production. Distinguish manual, mobile and automated equipment for corrugated board.
Manual machines for corrugated board are used for the manufacture of corrugated products of small size and quantity. All technological operations are carried out using physical strength operator without the use of electricity. A manual machine for the production of corrugated board, the price of which is relatively low, finds its use mainly in the manufacture of additional elements from galvanized material in metalworking workshops and in construction organizations. Application for raw materials with a polymer or paint coating is not recommended. If there is a technical possibility, some of these mechanisms can be made independently, especially since the drawings of machines for corrugated board with manual drive easy to find on the internet.
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Manual machines for corrugated board
Mobile equipment is designed to organize the production of profiled sheets directly at the construction site. So equipment for the production of arched corrugated board is actively used in the construction of warehouses, airfield hangars, grain storages and other structures that have arched elements in the project. Mobile equipment and arched corrugated board make it possible to build large-sized arched structures at a fairly high pace, while significantly saving on the supporting frame of the building.
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Equipment arched corrugated board
Automated equipment for the production of corrugated board, the price of which is the sum of the cost of its individual components, is an automatic or semi-automatic line, consisting of a set of machines and mechanisms mounted in a certain order.
Myself technological process as follows:
- Sheet hot-dip galvanized steel in the form of a roll is fixed on a cantilever decoiler.
- The raw material in the form of a strip is sent to a profiling rolling mill, which has several pairs of stands. The quality of the resulting profiled sheet directly depends on their quantity. Each separate stand has 2 sets of rollers of a given geometry, which are fixed respectively on the upper and lower shaft.
- The profiled sheet gradually approaches the intended geometry of the product during successive passage through the stands.
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Production of corrugated board equipment
Equipment for the production of profiled sheets can be equipped with punched electromechanical shears, roller tables or stackers, as well as a system automatic control equipped with touch control. Some manufacturers of corrugated decking equipment complete the kit with a measuring clamp, a table and shears for cutting edges, a waste collection and disposal device.
As part of a standard line for the production of profiled sheets, there are:
- Cantilever decoiler of a roll of raw materials - coated galvanized sheet (load capacity of this mechanism can reach 10 tons).
- A rolling mill for profiling a smooth sheet (it is optimal to have a simultaneous rolling scheme at a speed of at least 22 m/p per min).
- Guillotine shears with blades having the shape of a sheet profile.
- Receiving device for finished products.
- Automated system that controls production processes.
In addition to the specified equipment, to organize the production of corrugated board, a heated room will be required, in which there is a crane-beam and an even coating of the industrial floor is made.
Cantilever coil decoiler with a load capacity of up to 10 tons is designed to unwind metal from the strip and feed it to the rolling mill of the production line. The device is equipped with automation that allows you to control the sagging of the material loop between the rolling mill and the unwinder itself.
The rolling mill is the main element and the main mechanism in the set of equipment for the production of corrugated board. It is with its help that a given profile is obtained from a smooth workpiece. In its composition, the mill has working rolling stands, which perform sequential bending of the profiled sheet. In addition to the working stands, there is a filling stand, control cables, power cables and electric drives on the common frame.
Guillotine shears are designed to cut the resulting profiled sheet to the size specified by the operator. The geometry of the scissor blades completely repeats the geometry of the product, which ensures a high-quality cut without bends and burrs. To ensure high rigidity of the entire structure, the shears are mounted on the same frame as the rolling mill.
The receiving device is designed to form bundles of finished products. The length of this line element depends on the type of corrugated board.
The automated control system connects all devices of the line into a single network, controls its operation, the occurrence of freelance and emergencies and provides control of the entire complex from the central operator's console.
In general, the investment of financial resources in the production of corrugated board, according to many experts, is quite economically justified. Since the demand for this material in the coming years will grow steadily. Consequently, the market for this product will only increase. But in order to adequately compete in this market, it is necessary to use only high-quality production equipment that can produce material that meets all established standards.
Of course, in order to save money, you can purchase equipment for the production of BU corrugated board, but in this case, you should carefully study the offer and its technical condition, since many manufacturers, updating their production fleet, put up for sale machines that are on the verge of running out of their resource.
The same recommendations apply to equipment for the production of corrugated board from China. Among noteworthy specimens, outright imitations are sometimes found. famous brands that have nothing to do with the original machines.
The production of a reliable, small in weight and inexpensive profiled sheet used in the construction industry of our days is carried out on special manual and automatic equipment.
1
Decking - universal modern material for the construction of low-rise buildings, wall cladding, roofing and other construction tasks, it is made from cold-rolled galvanized steel sheet. To give such rolled products the required shape, only two methods are used - hot and cold rolled. Both of these operations involve the passage of flat sheets of steel through special shafts.
Hot-rolled technology, due to its features, is available exclusively at large metallurgical plants.
But the cold rolling of steel billets in order to obtain from them can be performed in semi-professional and even amateur conditions. The main thing here is to choose the right equipment and learn how to use it correctly.
The cold rolled production technology consists of two consecutive procedures. First, the workpiece is passed through the rollers, and then the resulting corrugated board is cut according to the given geometric sections. The shape of the rollers determines, as you yourself understand, the shape of the finished product.
The simplest manual machine for the manufacture of profiled sheets is able to "give" us products of only one shape. In those cases when an automated line for the production of profiled sheets is used, it, as a rule, makes it possible to obtain products of different assortments and shapes. Such diversity is achieved due to the fact that automated equipment makes it possible to change the settings of the rollers.
2
Production is possible on installations of three main types:
- manual machine;
- mobile (mobile) equipment with partial automation of work operations;
Any person can use an elementary machine for the production of profiled sheets, but on condition that he is ready to make quite serious physical efforts to process steel sheets. On manual settings Usually billets of small thickness are rolled. The quality of the resulting products is at a low level. In most cases, such a machine is used for the production of profiled sheets for fences and fences.
Manual equipment does not have to be purchased in ready-made. On the Internet there are a huge number of detailed drawings and diagrams, guided by which you can independently make the simplest bending machine. We note again - it makes no sense to use it for the production of really high-quality profiled sheets. You simply won't be able to do anything.
Partially automated equipment for the production of corrugated board allows you to produce many times more professional products. Such units are equipped with an electric drive, they have a relatively small weight, which allows them to be carried and used directly at those facilities where low-rise construction is carried out, the construction of storage facilities for agricultural products and warehouses, hangars, fences, and so on.
Semi-automatic equipment is in no way inferior to fully automated lines in terms of the efficiency of its work and the quality of the profiled products. At the same time, it is mobile, which in some cases is of great importance.
A stationary automatic line is a whole complex of units. Depending on the specific configuration, it may include the following settings:
- directly rolling mill with rollers of several sizes;
- device for cutting profiled sheets;
- application equipment for finished products polymer coating.
Also, as part of automated lines, there is sometimes a unit for loading operations. It is clear that such complexes have a high cost. But their performance is many times greater than the capabilities of manual and semi-automatic machines. It makes sense to invest in automatic equipment when you plan to work long and fruitfully in the field of manufacturing and selling profiled sheets with all kinds of geometric parameters.
3
Experts say that the minimum set of automated equipment for the production of high-quality profiled sheets should include the following mechanisms and fixtures:
The corrugated board production line is controlled by a special system. It can be both relatively simple and really complex. A simple control system does not provide high level automation of the production process, but people with low qualifications can work with it. But a complex equipment control complex increases the efficiency of the line. True, not everyone will be able to deal with such a system, for its use it is necessary to attract specialists with a large amount of technical knowledge.
4
Billet in the production of profiled sheet products on automatic lines directly depends on the number of rollers for rolling. They are placed in pairs one above the other. There is a small gap between the individual pairs of rollers. The steel sheet from which the corrugated board is made is slightly less than the specified gap in thickness (and sometimes these figures are the same).
The initial workpiece is passed through the rolling shafts, and this procedure is carried out several times in a row, since it is usually impossible to achieve the required sheet shape in one pass. In one run, the workpiece is bent between the rolls by a certain amount. At the same time, minimal pressure is exerted on it, which ensures a perfect result of the final deformation.
It is important not to overdo it with the number of pairs of rolls. If the workpiece is passed through too many of them, there is a possibility that the zinc coating of the steel sheet will be destroyed. In addition, the quality of profiled sheets is influenced by the quality of steel alloys from which rolling shafts are made and the level of cleanliness of their processing.
Experts advise to purchase equipment from foreign manufacturers (for example, Finnish) or domestic production lines, and never pay attention to units for the production of profiled sheets from Chinese companies. And the last. If possible, it is better to buy new rather than used profiled sheet production lines, since the technical capabilities of the latter are usually at a very low level due to their wear and tear.
