A roll forming shop, not a trading house
We buy coil, cut our own rolls, and run the line ourselves. That matters to you because when a section is out by half a millimetre, there is nobody in between to blame — and nobody to wait on for the fix.
How a job runs
Drawing to dispatch
Five steps, in this order, every time. You are asked to approve once — at the first-off — and nothing goes into production until you do.
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Step 01
Send the section
A DXF, a PDF, or the old part in a courier bag. Any of them is enough to start.
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Step 02
Tooling
We produce the roll tooling and dies for your section.
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Step 03
First-off sample
We run a trial length and send it with a dimension report. You check it against your drawing and approve.
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Step 04
Production
Rolled and cut to length to the approved sample, then quality checked batch by batch.
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Step 05
Dispatch
Bundled and scheduled against your build plan, so sections land when the line needs them.
The work
Coil in one door, sections out the other
Cold roll forming is a continuous process. A coil of flat metal is straightened, then fed through a line of shaped roller pairs that each add a few degrees of bend. By the last station the strip holds its finished shape, and it is cut to length before it leaves the machine.
What separates a good section from a bad one is the roll design that decides how much bend happens at which station — get it wrong and you get edge wave, twist, or a section that springs back out of tolerance a week later. That design work is the part we keep in-house.
Plant
What is on the floor
| Machine | Notes |
|---|---|
| Raw material storage | GI, MS and steel coils kept indoors, ready for the line |
| Decoiler | Unrolls the coil and feeds it into the line |
| Straightener | Flattens the strip before forming |
| Roll forming machine | Forms each profile in one continuous pass |
| Automatic cutter | Cuts every section to length as it comes off the rolls |
| Inspection table | First-off and batch checks against the approved sample |
| Packing table | Sections bundled and strapped for transport |
| Finished goods storage | Finished sections held ready for dispatch |
Quality
Checked against the sample you signed
Every profile has an approved first-off. That physical sample, and the dimension report that went with it, is the reference for every batch afterwards — not a drawing sitting in a drawer, and not somebody's memory of how the last run went.
- First-off approval. Nothing runs in production until you have the trial sample in your hand and say yes.
- In-process checks. Section and cut length measured through the run, logged against the batch.
- Material traceability. Coil recorded against the mill test certificate, so a batch can be traced back to its heat number.
- Tooling logged and stored. Rolls kept under your part number, so the repeat order comes off the same tools as the first.
- ISO 9001:2015 certified. Our quality system is audited to the standard.
On record
Every check, written down and dated
Our quality system runs on paper as much as on the line. Each of these is filled in, signed and dated as the work happens, and filed against the job — so a part can be traced back long after it has shipped.
Control & planning
Control plan, PFMEA, process flow and layout, sampling plan and product specification for every profile.
Checks on the line
First and last piece, in-process QA checks, 4M condition checks, PDI check sheet and the shift log book.
Measurement & traceability
Instrument calibration records, Cp/Cpk capability studies and coil-to-batch traceability to the heat number.
Improvement
Kaizen records, fishbone analysis and corrective-action plans for anything that shows up on the line.
Housekeeping & upkeep
Raw-material and finished-goods inventory, preventive machine maintenance and the cleaning schedule.
Quality system
Quality manual, work instructions, master list of documents and operator training records.
Straight answer
Roll forming is not right for every job
It is worth knowing before you spend money on tooling. Here is where we save you money, and where you should go somewhere else.
A good fit
- You buy the same section again and again, in hundreds or thousands of metres a year.
- The section is long and thin, in sheet gauge, and constant along its length.
- You want it delivered cut to length and ready to fit.
- A press brake is giving you variation between operators that your jig cannot absorb.
Go elsewhere
- One-off pieces or a few metres. Tooling will never pay back — use a press brake.
- Hot-rolled structural sizes, or plate much above [3 mm]. That is a rolling mill's work.
- Solid or hollow shapes with varying wall thickness. You want an extrusion, not a formed section.
- Sections that change shape along their length, or need tolerance tighter than roll forming can hold.
Next step
Send us a section
A drawing, a photo of the old part, or just the dimensions written down.
Sandip Kareker, Partner
Call +91 92708 87161