Roll forming lines for pallet racking beams – Gasparini S.p.A.

We design and deliver roll forming lines dedicated to the production of beams and cross beams for industrial racking and mezzanine floors. These solutions are engineered for racking manufacturers who demand high productivity, dimensional repeatability, and full process integration.

Key technical features of roll forming lines

• Thickness range: up to 2 mm (0.08 in)
• Production speed: up to 60 m/min (197 ft/min)
• Roll forming technologies:
  • TWIN
  • PRO
• Setup times:
  • TWIN: less than 5 minutes
  • PRO: less than 1 hour
• Profile lengths: from 1,000 mm to 6,000 mm (39 in – 236 in)
• Examples of maximum profile dimensions:
  • Box beams, step beams up to L 60 × H 200 mm (2.4 in × 7.9 in)
  • C profiles up to L 800 × H 80 mm (31.5 in × 3.1 in)

Auxiliary technologies for roll forming

Our roll forming systems are engineered to integrate the main processing stations, delivering turnkey lines for racking beam production:

• Straightening system
• Punching system
• Cutting system

In-line options

Gasparini designs and integrates optional in-line equipment to increase efficiency, maximize uptime, and minimize changeover times:

• Automatic coil loading system
• Sheet joining unit
• Quick die change system
• HF automatic welding unit for connectors
• Automatic unloading system
• Automatic stacking, packaging, strapping, and labeling system

Quality, tolerances, and material yield

Surface quality and tight dimensional tolerances are essential for beams and cross members that must be precisely joined or interlocked.

The roll forming process, combined with optimized cutting, significantly reduces spring-back, improving final product yield and minimizing scrap and rework.

Software and industry 4.0 integration

Gasparini software is designed to optimize the production process and make the operator more efficient through dedicated interfaces and intuitive workflows. Key features include:

• Dedicated HMI interfaces for roll forming line control
• ERP integration for seamless data synchronization with the customer’s management system
• Compatibility and flexibility in data import/export across multiple formats, supporting production, traceability, and reporting

Gasparini roll forming solutions

Our roll forming machines for racking beams and cross members are engineered to deliver efficiency, quality, and flexibility. Key advantages include:

• Reduced setup times and increased machine availability (TWIN for quick changeovers)
• Dimensional repeatability and surface finish suitable for pallet racking applications
• Modular and fully integrable lines: from coil to stacking
• Proprietary software turning data into operational efficiency and reporting

Are you evaluating a custom roll forming line for your racking beam production?
Contact our sales team for a technical consultation and a tailored proposal: request a live demo or schedule an on-site visit.