Shelving roll forming machine

precisionquick-changecustom

Overview
Gasparini S.p.A.'s roll forming lines for supermarket shelving uprights produce shop shelving uprights with precision punching, integrating decoiling, strip feeding, punching, roll forming, cutting and downstream operations such as notching and end forming.

The production challenges of retail shelving uprights
The upright is the vertical load-bearing column of supermarket shelving: a closed rectangular-section profile obtained by roll forming followed by longitudinal welding and characterized by a high number of holes along its length. Positional accuracy of these holes is essential to ensure interchangeability and correct in-line assembly of hooks and cross members.

Technical sheet
Thickness: up to 3 mm
Production speed: around 18–20 m/min
Setup time: Less than 10 min
Flexible roll forming technology: Interchangeable, Twin

Process sequence

• Decoiler and strip feeding – continuous unwinding of pickled steel strip (material is pickled steel; painting occurs later outside the roll forming line).
• Strip accumulator system – stores strip during coil joining to allow continuous production and zero scrap during coil changeover.
• Punching with mechanical press – complete punching pattern is made on the flat strip before roll forming; mechanical press chosen for its robustness and high-frequency capability.
• PRO roll forming system with spacers – progressive bending of the strip into the final cross-section; allows different base widths and heights with ~1 hour changeover.
• High-frequency welding with water cooling – longitudinal welding of the closed rectangular section with water cooling to control heat.
• Additional end-forming operations – notching and end operations performed downstream after cutting.
• Cutting unit – profile cut to programmed lengths from 1,500 to 2,500 mm.

Additional processing operations for shop shelving uprights
Notching operations and end-forming processes that prepare profile ends are typically performed after cutting as supplementary downstream stations, delivering fully finished uprights without external reworking.

PRO system with spacers

• Size changeover to produce different base widths and heights (setup time approx. 1 hour).
• Interchangeable cassettes for modifying profile geometry.
• Greater flexibility and productivity; integration with strip accumulator reduces scrap and supports continuous production during coil changes.

Punching accuracy for shelf engagement
Punching determines modularity and reliability of shelf engagement; mechanical presses are commonly used to handle the high number of holes and maintain positional accuracy required for display and retail shelving systems.

Welding system
High-frequency welding with water cooling is normally recommended for this production; when used, customers often request a strip accumulator upstream of punching to allow head-to-tail coil joints without stopping the machine.

Line speed and productivity

• Typical operating speed: around 18–20 m/min.
• Lengths produced: from 1,500 to 2,500 mm (1 to 2.5 m).
• Material: pickled steel.
• Typical thicknesses: up to 3 mm.
• Possibility of integration with end-of-line operations (strapping, labeling) to optimize workflow.

Industry 4.0 integration
The line connects to the customer's MES through a bidirectional interface: production programs are uploaded to the machine and process data are recorded batch by batch to ensure traceability and alignment with plant scheduling.