01
ERW Tube and Profile Mills
Turnkey lines for welded steel tube from Ø10 to Ø406 mm and square/rectangular profiles from 10×10 to 300×300 mm.
- Tube diameter
- Ø10 – Ø406 mm
- Wall thickness
- 0.50 – 12.70 mm
- Line speed
- up to 160 m/min
Direct Forming Tube Mills
Direct forming lines that produce 20×20 – 120×120 mm square and rectangular profiles with no roll change — sizes are set from the computer.
- Profile size
- 20×20 – 120×120 mm
- Wall thickness
- 1.10 – 6.00 mm
- Line speed
- up to 130 m/min
- Roll change
- None
Overview
On a direct forming line the strip is shaped straight into a square or rectangular profile, without first being formed into a round tube. Roll positions are set by computer control, so you do not need to change rolls to move to a different size.
Roll investment and set-up times are kept to a minimum, and because the same profile can be produced from a narrower strip, you also save material. The BPL series combines high speed with low operating costs.
Key innovations
- Change the product size by computer control without changing rolls
- Minimum roll set-up time
- Lower roll tooling costs
- High production capacity
- Less labour required
- Easy maintenance and lower operating costs
- Easy-to-use software and operator panel
- Produce the same profile from a narrower strip
BPL series technical specifications
Scroll sideways to see the full table| Model | Profile size (mm) | Wall thickness (mm) | Max. speed — S355 / St52 (m/min) | Max. speed — S245 / St37 (m/min) |
|---|---|---|---|---|
| BPL 200 | 20×20 – 50×50 | 1.10 – 2.50 | 110 | 130 |
| BPL 240 | 25×25 – 60×60 | 1.35 – 3.00 | 100 | 120 |
| BPL 320 | 30×30 – 80×80 | 1.50 – 4.00 | 90 | 105 |
| BPL 400 | 40×40 – 100×100 | 2.00 – 5.00 | 80 | 90 |
| BPL 480 | 50×50 – 120×120 | 2.00 – 6.00 | 70 | 80 |
* The machines listed are standard models; we engineer lines for the sizes and capacity you need.
Line layout
Explore the line from start to finish
Drag the plan, zoom in or tap a station. Units with photos open in detail with a single tap.
01
Uncoiler
02
Coil opener and leveller
03
Automatic shear welder
04
Rotator
05
Accumulator
06
Forming entry section
07
Forming section
08
Welding section
09
Scarfing section
10
Cooling tunnel
11
Turk’s head
12
Flying saw
13
Conveyor and packing
Whole line
Direct Forming Tube Mills
The line consists of the following units
- Decoiler
- Decoiler and straightening unit
- Automatic strip end welder
- Accumulator
- Forming entry section
- Forming section (computer-controlled adjustment)
- Welding section and high-frequency welder
- Turk’s head section
- Flying cold saw
- Conveyor and packing section
- Electrical, hydraulic and automation group
- Installation, commissioning and 1-year full warranty
Direct Forming Tube Mills
Line units
Tap a card for details on each unit.
01 / 10
Decoiler
The first unit, feeding the line. Built with a single or double mandrel; on double-mandrel types a new coil is prepared on one mandrel while the other feeds the line. Coil loading, brake and hold-down roll settings are controlled by the operator.
02 / 10
Decoiler and Straightening Unit
Corrects the leading end of the strip coming from the decoiler and guides it to the straightening unit for a clean entry into the line.
03 / 10
Automatic Strip End Welder
Joins the tail of the finished coil to the head of the new coil. Shearing, joining, clamping and welding are all automatic, so the line runs without interruption.
04 / 10
Accumulator
Stores strip so that the line does not stop during strip end welding, keeping the profile mill running continuously.
05 / 10
Forming Entry Section
Aligns the strip coming from the accumulator and feeds it into the forming section in a controlled way.
06 / 10
Forming Section
The strip is shaped directly into a square or rectangular profile without first being formed into a round tube. Because roll positions are set from the computer, no roll change is needed when the size changes.
07 / 10
Welding Section
The edges of the formed strip are heated by the high-frequency welder and pressed together by squeeze rolls; the outside weld bead is removed immediately after welding.
08 / 10
Turk’s Head Section
The section where the profile receives its final dimensions and corner shape, and where its straightness is corrected.
09 / 10
Flying Cold Saw
Cuts the profile to the required length without stopping the line. It travels on a linear slide and performs all functions automatically, synchronised with the line.
10 / 10
Conveyor and Packing Section
Cut profiles are carried by conveyor to the kick-off unit and packed in square bundles on both sides of the stacking table.
Direct Forming Tube Mills
Gallery
Direct Forming Tube Mills
Frequently asked questions
Share your material, product dimensions and capacity target — our engineers will prepare a technical proposal tailored to you.
How does a direct forming line differ from a conventional tube mill?
On a conventional mill the strip is first formed into a round tube and then into a profile. On a direct forming line the strip is shaped straight into the profile, and size changes are made from the computer with no roll change.
Which profile sizes can I produce?
The BPL series produces square and rectangular profiles from 20×20 mm to 120×120 mm, with wall thicknesses of 1.10 – 6.00 mm.
How much can I save on roll tooling?
Because no separate roll set is needed for each size, roll investment and stock costs drop significantly, and set-up time is kept to a minimum.
Production lines
Other production lines
03
Coil Slitting Lines
Slitting lines with optional double slitter head that cut 0.50 – 12.00 mm coils up to 2000 mm wide into strips of the required width.
- Sheet thickness
- 0.50 – 12.00 mm
- Coil width
- up to 2000 mm
- Coil weight
- up to 30 t
04
Cut-to-Length Lines
Cut-to-length lines that level 0.50 – 16.00 mm coils, cut them to the required length without stopping, and stack the sheets automatically.
- Sheet thickness
- 0.50 – 16.00 mm
- Coil width
- up to 2000 mm
- Coil weight
- up to 30 t
