Valjčna profilirna linija

Linia CZS Zeman

The line was manufactured in 2010. A complete modernization took place in 2020.

ZEMAN CZS LINE – SPECIFICATIONS
The fully-automatic "PURLIN" line, ZEMAN's flagship product, is designed for the production of open, cold-formed profiles, such as C, Z, and Sigma profiles, in various widths and shapes. This is made possible through fully-automatic adjustment of the roll forming tools. Coils up to 750 mm wide and sheets from 1.25 mm to 3 mm thick in grade S-390 or below can be processed as raw material. The machine is designed for manufacturing components up to 15 m in length. The width of the specially hardened roll forming tools is continuously adjustable via dedicated software. A fully integrated punching unit creates all types of fastening holes. The entire process is continuous—meaning the material does not stop for individual operations such as punching or cross-cutting. To ensure high production efficiency, the line speed is dynamically optimized. The machine brakes and accelerates automatically, with no operator intervention required.

A decoiler with a maximum working load of 15 tons is mounted on a trolley, allowing precise centering of the coil strip before feeding into the straightening machine.

The straightening machine, combined with a sickle-straightening system, flattens the material, ensures the required sheet flatness, and reduces the curvature on the conveyor belt.

2. Punching area
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This section features five double “flying” punching portals that can be equipped with up to 20 small (up to 40 mm) or 10 large (up to 100 mm) punching tools (punches and dies) for producing fastening holes. A combination of tools is also possible.

3. Pre-cut shear
A "flying" shear is used to pre-cut the holes for the cutting shear. This process ensures material continuity and results in a more precise profile shape, especially at the beginning and the end. This is an adaptive guillotine that adjusts the width of the cut hole to the width of the strip.

4. Guiding trolley/SIGMA modules
The guiding trolley centers the coil strip before entry into the roll former. It can be replaced with the module for manufacturing Sigma profiles. For the production of S+ profiles, the guiding trolley is removed, and two Sigma modules are installed. These modules position themselves automatically and independently to the left and right.

6. Rotary cut-off saw
The rotary cut-off saw with hook blades separates the finished profile from the coil strip, utilizing the holes created by the pre-shearing device. As a "flying" cut-off saw, the strip does not need to be stopped during cutting. Depending on the required profile, a suitably aligned cutting cassette is used.

7. Discharge table
The discharge table serves to automatically eject the finished profiles from the roller conveyor. The elements are then manually grouped into a bundle. The design allows for easy bundling of the package. The table is designed to accommodate profiles up to 15 meters long and allows access by forklift or overhead crane to pick up the profile bundle.

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