MARKET TRENDS IN THE USAGE OF METAL PAINTED STRIP FOR ROLLFORMING APPLICATION
Dallan AndreaSales director of Dallan Spa
2
What we will cover:
• Short history or Dallan Spa, producer of Rollformers since 1978
• The focus in thin gauge material and specialization in rollformers for prepaintedmaterials
– The technical issues
– The characteristic of prepainted strips for rollforming application
3
What we will cover: continued
• The development of the production systems
– 1978 to 1990: production of rollformed sections
– 1990 to 2000: production of finished metal products.
– 2000 –Today: production of finished metal products, complete with assembly and packaging.
• Case Studies: history of thickness range development for aluminium rolling shutters and linear ceilings from 1978.
4
Dallan Spa: short history
• Established in 1978
– Engineering and Design
• 1982: Focus on thin materials
– From 0,2 to 2mm
– The markes requires specialists in processing ofprepainted strips
5
Facts and figures:
• In 34 years of activity Dallan Spa has:
– Developed and tested over 7000 rollf. sections
– Over 2300 machines and lines have been deliveredin 73 countries
– Turnover 2011: 24,7 M€
– 2011 export rate: 90,4% (53,2% outside the EU)
9
Technical issues in the rollformingof coated materials
• The rollforming process
• Peripheral speeds and possible scratching
• Bend radiuses and coating flexibility
10
The rollforming process
• The process of progressive bending of a metal strip by using shaped rollers
+ Immagine fiore di profilatura
11
Peripheral speeds
12
0
100
200
300
400
500
600
700
74 78 82 86 90 94 98 102106110114118122126
Neutral speed and peripheral roller speeds (mm/sec)
Periph. Speed upper roll Periph. Speed lower roll
Neutral line speed
Solution
• Development of rollform flowers close to the neutral line to reduce the speed differences
• Use of polishedrollers
• Use of coatings withhigh resistance toscratching and wear(ISO 7784-2)
13
Bend radiuses
• Rollforming allows the production of complexshapes
• In the praxis the internal bend radiuses are 80% to 120% of the material thickness, butthey can be even less
14
Characteristics of coatings
• The coating must be flexible to allow the bend(EN 13523-7)
15
Rollingshutter
T-bar
Trends in the production systemsand requirements for the coatings
• A short history of the development of Dallan production systems to analyze the market trends in the past 30 years.
16
1978-1990: rollformers
• Dallan produces rollforming machines on demand.
• From 1982 Dallan focuses on thin materials; this pushes the usage of prepainted strips.
• Market: 90% Italy.
17
1990-2000: Rollforming lines
• More and more clients start demandingmachines that allow the production of a completely finished product.
• Dallan specializes in production lines.
18
1990-2000: Rollforming lines
• The rollformer is integratedwith additional machines toobtain the finished product
• The customers demand reflectsthe worldwide trend towardsthe Lean Manufactuing model: “As Lean as a Line”
19
1990-2000: Focus on applications
• Dedicated lines for specific applications:
– Rolling Shutters (prepainted)
– Linear Ceilings (prepainted)
– T-bar for metal suspended ceilings (prepainted)
– Plasterboard sections (galv. steel)
– Open Cell metal ceilings(prepainted)
20
1990-2000: Focus on applications
– Venetian blinds (prepainted)
– Angle profiles for interior finishing
– Door frames (pvc-coated)
• 70% of the products required today to Dallan is made out of coated coils.
21
1990-2000: The requirementsfor coated materials
• It is necessary to process special shapes or embossings for manual assembly
– Snap-on manual assembly / joining systems withoutrivets or screws
• More resistance is required to the coatedmaterials
– Bending
– Stretch forming
22
1990-2000: The requirementsfor coated materials
23
• Example of snap-onassembly on a lightingfixture body 600x600mm
2000-Today: Production Systems
• Customer’s request lead to more advancedproduction systems.
• Once the product is made, it is required tointegrate either
– Assembly
– Packaging and subsequent logistic
24
2000-Today: Rolling shutters
27
• Main application:
– sun protection
– energy saving
• The slats are inserted and wound on an axis
• The wound up curtain is located insidean aluminium box
2000-Today: New Challenges
• Once the product is in the box it’s no longerpossible to check it
• Higher demand for high and constant qualityof the coated strips
• Request for visual controls of the rollformedproduct before it is in the box
• No lubrication is possible, limited dry times
33
Case History: material thicknessin coated materials – Rolling shutters
• Material: aluminium
• Thickness range 0,21 to 0,5
• High competition: Search for reductionproduct cost (lower thickness and band width)
• 268 single original designs
• Only in 2011, 21 new designs have beendeveloped
34
Roller shutter slat: a functional section• It must work throughout
the life of the blind (1c/day)
• Domotic application with tubular motor → smoothwinding with low force
• Continuous frictioncoating vs. coating
• Application in hot countries: technical aspects
35
Rolling shutters
36
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
1980 1985 1990 1995 2000 2005 2010 2012
Trends in the thickness of Aluminium for Rolling Shuttersfor windows (up to 55mm height)
LOW MEDIUM HIGH RES.
Case History 2: Metal Ceilings
• Dallan is focused on metal ceilings since 1982
• Material: prepainted aluminium and steel
• Thickness range: 0,3-0,5 (Aluminium)0,35-0,5 (Steel)
• High competition
• Market subject to architectural trends
37
Metal Ceilings: technical aspects
• It is a static and aesthetical application
• Low weight is a plus for suspended ceilings
• Metal ceilings in the event of fire
• User-friendly assembly is required
• Most common parameter for customers isCost per square meter
• Most common solutions: Cell grid (lay in and clip in), Open Cell, Linear Ceiling
39
Linear Ceilings - Aluminium
40
0
0,1
0,2
0,3
0,4
0,5
0,6
1980 1985 1990 1995 2000 2005 2010 2012
Trend of the thickness of the Aluminium used for linear ceilings and Open Cell Ceilings application
LOW HIGH
Top Related