Hayes Dual Level Rollformer

Hayes Dual Level Rollformers are a great option for when floor space is limited. They allow for two profiles in the same basic footprint as a Single Level Rollformer. They are available in a wide range of specifications that can be customized depending on your requirements.

From Cladding and Decking to Roofing and Fencing lines, our lines are designed to support most industry-standard coatings and coil sizes, including Galvalume/Zincalume, Coloursteel, Resin coatings, and more.

Dual Level Rollformers are available in a wide range of specifications that can be customized depending on your requirements. It’s a cost-effective way to pair a high-volume profile with a low volume profile.

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Dual Level Rollformer Standard Components Details

Hayes International FAQs
Dual Level Operation
  • Two sets of tooling with staggered pedestals allow for multiple profiles in the same footprint as a Hayes Single Level Rollformer.
  • Each toolset is driven independently via a dedicated electric gear motor.
Infeed
  • Dual level adjustable infeed guides to suit coil discrepancies and control under/overlap length; positioned via Siko type screw adjustment.
  • Dual level built-in lubrication system with felt wick applicator that applies lubricant to both sides of the sheet.
  • Manual pull-across slitter or a powered slitter with D2 hardened steel knives to reduce waste material.
Chassis And Pedestals
  • Fabricated steel chassis in segments for easy handling, painted with a lacquer finish.
  • Reference marking and leveling feet for ease of alignment.
  • Pedestals are a heavy-duty welded steel design with all working surfaces precision machined. Pedestals are height offset to allow one profile to run above another.
  • Each pedestal houses heavy-duty self-aligning bearings with tooling shaft locking collars.
Tooling
  • Multiple tooling options are available depending on the profile spec and the line speed required. All options are precision CNC machined in house. These include:
    • Solid K1045 steel tooling rolls with a hard chrome finish.
    • Segmented D2 Steel through hardened to KC60 grade.
Rollformer Drive
  • Driven by dedicated VFD Electric motors mounted inside the chassis with each toolset individually driven.
  • Power transmitted via heavy duty chain and sprocket.
  • Secured via Bonfix style couplings.
  • Each bottom roll of tooling is driven, with the first stations coupled via spur gear to aid traction.
Guarding
  • Guarding covers tooling rolls and transmission.
  • Welded steel and mesh construction painted with lacquer finish.
  • 2 Configurations available: 'Lift up' guards that open upwards with the aid of gas struts, or interlocking tunnel guards that open via sliding on track and rail system.
  • All guards are equipped with interlocking safety switches integrated into the safety system.
  • Polycarbonate guarding option available.
Guillotine
  • Heavy-duty twin pillar post-cut guillotine with dual-level operation.
  • Hydraulically operated via a dedicated power pack housed inside the chassis.
  • Replaceable D2 through-hardened steel blades precision that are ground and sharpened.
Control System
  • Dedicated operator's console controlled via a PC and Hayes SmartCut multi-batching control.
  • Fully instrumented controls capable of operating in manual or automatic modes.
  • Data download and order entry facilities, fault-finding capability and operating safety system.
  • Can be configured to run select 3rd party control systems.
  • ERP integration capability (subject to controller type) with production reporting, scrap monitoring, etc.

Request A Quote

If you’re ready to take the next step, let us know below. One of our team can get in touch to talk through your project. If you’d like to share a drawing, attach it below. We look forward to receiving your enquiry.

Optional Rollforming Equipment

Coil Handling

Hayes International offers a range of coil handling equipment, including Uncoilers, Coil Cars, and' hands-free’ systems for feeding coils.

Coil Car

Increase efficiency with Hayes Coil Cars. Easy coil loading without stopping production, featuring electric and hydraulic systems. 

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Hands Free System

Safer, easier coil feeding with Hayes 'Hands Free' system. Minimal operator intervention and pneumatic-driven peeler arm for efficient operation. 

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Linkage Uncoiler

6-tonne capacity with hydraulic drawbar system. Manual or automatic operation for seamless coil handling. 

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Twin Mandrel Uncoiler

Hayes Twin Mandrel Uncoilers offer fast, efficient coil changes for increased productivity. They have a 6-tonne capacity per side and 360° rotation. 

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Wedge Uncoiler

6-tonne capacity with hydraulic wedge system for reliable coil grip. Operates manually or automatically, featuring heavy-duty bearings and a dedicated hydraulic powerpack. 

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Finished Product Handling

Hayes International offers a range of product handling options, from fixed runout tables for manual offloading to drop tables. These tables stack finished products after each cut, ready for packing. 

End Tamper

Compact, time-saving accessory for automatic sheet alignment post-cut. Available in pneumatic or electric operation. 

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Runout Table

Support sheets exiting machines to prevent damage. Single and dual level options with automatic pneumatic drop arms. 

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Optional Panel Mill Equipment And Extras

 Hayes International offers a range of optional equipment to aid in production and decrease down time.

Powered Slitter

Motorized upgrade for automatic coil slitting. Operates via Hayes Smart-cut or manually, ensuring efficiency and safety. 

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Flying Shear

Enhance production speed with continuous cutting. Electric motor and servo-driven for precise cuts at 60m/min. Compatible with Single Level Rollformers and coil widths of 940mm to 1250mm. 

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Plastic Applicator

Smoothly applies film to coils with no folds or air bubbles. Suitable for single and dual level machines. Manual film application and cutting for precise control. 

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Fletcher Dimond Roofing

Case Study: Fletcher Dimond Roofing

General Manager Damien Sauni needed a partner to build a fully custom Rollforming machine — one that could manage the high output of a diverse product offering, with minimal operator intervention. After a long relationship of 40 years, Hayes International was, in Damien’s eyes, the best partner for the job. 

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Custom Metal Industries

Case Study: Custom Metal Industries

Custom Metal Industries is a 4th generation family business based out of Greenfield Indiana and has used Bradbury Group and Hayes Machines since 1960.  Custom Metal Industries and Hayes have grown together, in a true partnership lasting for generations.

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Spec A Machine

Hayes Rollformers are built for the most robust production lines. Hayes International has been manufacturing Rollformers for over 60 years and have a reputation as one of the world's top manufacturers of Rollformers and Rollforming equipment.

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