PRODUCT REVIEWS
Electric high-speed roll forming system
Dallan’ s major innovation in thin sheet metalforming is its Full Electric 120 roll forming system.
“ This advanced platform marks a new standard in productivity, energy efficiency and automation— delivering everything that manufacturers need for lean coil fabricating. Engineered for high-speed, just-in-time production and seamless integration with automated packaging, the Full Electric 120 is not just a machine— it’ s a complete production system,” the Italian coilprocessing specialist told ISMR.
“ Installation is no longer a bottleneck. The Dallan Full Electric 120 features a monoblock structure that fits inside a standard container and can be fully installed in just four days. Its compact design includes a forming unit; prepunching and embossing modules; a servoelectric flying shear; a soundproof cabin; scrap evacuation and a Siemens control desk. Requiring just three connections— power, air and internet— the system is designed for fast set-up and minimal downtime,” it added.
Powered by Dallan Electric servo actuators, the Full Electric 120 eliminates hydraulics completely.
“ That means no oil changes or leaks; centralised automatic lubrication;-34 % energy use compared to hydraulic systems; patented tools with < 0.55 sec. cycle time and regenerative energy recovery from the flying shear. It’ s a cleaner, quieter and more sustainable production platform that lowers operational costs while increasing uptime,” outlined Dallan.
The Full Electric 120 offers manufacturers up to 120 metres / minute on 0.8mm material, up to 60m / minute on 1.2mm material with COMBI gearbox and configurable roll forming stations( 8, 12 or 16 passes). There are prepunching, marking and embossing options and SMED-style rapid format changes.
“ Future-ready and fully modular, the platform adapts to new production needs and profile types. Our D-Touch software, is the digital brain behind the Full Electric 120. Developed in-house, D-Touch enables realtime control via Siemens PLC and industrial PC; ERP and MES integration and job list management directly on the touchscreen. Integrated teleassistance, full production statistics and logs plus a seamless connection to coil warehouse systems is also possible. This allows for true Industry-4.0 / 5.0 manufacturing: efficient, connected and optimised,” added Dallan.
‘ Coil To Pack’
Dallan has also developed‘ Coil To Pack’, an advanced packaging line that processes up to 35,000 metres of profiles in eight hours( profiles from 2.4 – 8m and 0.3 – 1.2mm thick) as well as vertical and horizontal bundles.
The line also features auto-regulated stacking, strapping and wood insertion and speeds of up to 160m / minute with 4m profiles. Its modular configuration has seven compact units.
“ By synchronising directly with the Full Electric 120 via D-Touch,‘ Coil To Pack’ ensures that profile lengths match job site specs exactly; fewer handling errors; less labour and faster installations. There is no cutting or waste at the construction site,” explained Dallan.
“ Together, the Full Electric 120 and‘ Coil To Pack’ create the ultimate Lean Manufacturing solution— combining full electric motion; high-speed output; intelligent software; automated packaging and real sustainability,” it concluded. n
www
. dallan. com
Automation and integration for press lines
A five-minute stop is easy to miss in the moment. But a thousand five-minute stops show up in the statistics. AP & T is now rolling out a new control system in which machine learning helps a press line to find its own optimal rhythm, part of a broader initiative in which AP & T aims to help manufacturers get significantly more out of their existing press lines.
“ With the right automation and integration, we can often double our customers’ output using the same presses they already have in place,” said Jörgen Theander, Product Manager Automation, AP & T.“ We usually say that automation is the muscle, but integration – that’ s the brain. Because that’ s where real value is created. That’ s where we make sure all parts of the line work together in the best possible way,” he added.
Jörgen Theander, Product Manager Automation, AP & T.
Regardless of the press manufacturer, AP & T integrates them with its automation and takes full responsibility for the entire line system and its performance.
“ We review the big picture with the customer, look at how much inventory there is, what the production flow looks like and identify the bottlenecks. If they have a lot of semifinished material waiting between stations, that is a sign that production is not fully connected. Then we can help to find a solution that reduces that kind of tied-up capital and gets throughput moving. That naturally gets the customer’ s business moving as well,” explained Jörgen Theander.
AP & T’ s new control system has the capacity for more dynamic functions and offers expanded production engineering capabilities. Above all, however, it will be able to optimise its own cycle using machine learning, in which the system validates each cycle and ensures that the machine runs fast where it should run fast, and slow where that is best. In this way, concluded AP & T, wear and downtime are reduced while reliability increases. n
https:// aptgroup. com /
46 | ismr. net | ISMR July / August 2026