Upright rack roll forming machine

for shelvingwith cuttingpunching

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

Technical specifications
Product: Uprights for supermarket shelving
Profile section: Closed rectangular section, longitudinally welded
Material: Pickled steel
Lengths: From 1,500 to 2,500 mm
Roll forming system: PRO with spacers (production changeover ~1 hour)
Punching: High-frequency in-line mechanical press
Accumulator system: Coil joining without stopping the line, zero scrap
Welding: High-frequency with water cooling
Additional operations: Corner notching and downstream head/tail operations
Industry 4.0 integration: Bidirectional interface with customer's MES

Punching in upright production
Punching is the main technical challenge because uprights require many holes per unit length. An in-line mechanical press is used to sustain the high-frequency cycles needed for dense punching patterns. The actual productivity of the system depends significantly on punching density and complexity.

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.

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.

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.

The accumulator system: how Gasparini solves line stoppages

• Line continues producing during coil joining with no interruptions.
• Accumulated strip is gradually released upstream of the press during the joining stop.
• Zero material scrap between coils.
• Productivity is not affected by coil change frequency, important for high-volume production.

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.

Configure the roll forming line for your uprights

• Mechanical press configuration according to punching pattern complexity.
• Accumulator system sized to production volumes and coil change frequency.
• Selection of the most suitable roll forming system for dimensional and profile geometry mix.
• Integration of supplementary end-forming operations downstream.
• Optimization of production logic to reduce downtime and maximize hourly productivity.

Caractéristiques / spécifications techniques

• Product: Uprights for supermarket shelving
• Model / system: Roll forming lines for supermarket & shop shelving uprights
• Profile section: Closed rectangular section, longitudinally welded
• Material: Pickled steel (not pre-painted)
• Thickness: up to 3 mm
• Lengths: 1,500–2,500 mm
• Typical operating speed: around 18–20 m/min
• Setup / changeover: PRO system with spacers, production changeover ~1 hour
• Punching: In-line high-frequency mechanical press (for high hole density)
• Accumulator: Coil joining without stopping the line; zero scrap
• Welding: High-frequency longitudinal welding with water cooling
• Additional operations: Corner notching, end-forming, head/tail operations downstream
• Cutting: Programmable cut length (1.5–2.5 m)
• Industry 4.0: Bidirectional MES interface for program upload and batch traceability