🇸🇦 Saudi Arabia
C/Z Purlin Production Line
Steel Fabrication Factory, Riyadh
Full CZ purlin line with automatic stacking system. Replaced European imports with local production.
+40%Capacity
16 moROI Period
25 t/dayOutput
Case Studies
Global Success Stories
Proven cold roll forming & tube mill solutions across 20+ countries — with real ROI data
20+Countries Served
500+Projects Completed
99%Customer Satisfaction
300%Avg. ROI
<2%Material Waste
Region:
Type:
Project References
Explore our installations across industries and regions. Each project represents a partnership built on precision, reliability, and measurable results.
🇻🇳 Vietnam
Roofing Panel Roll Forming Line
Roofing Materials Factory, Ho Chi Minh City
Double-layer roofing panel line with automatic decoiler, pre-shear, and stacker.
18 moROI Period
<2%Waste
3 opsvs 8 before
🇷🇺 Russia
Industry 4.0 Retrofit
Metal Processing Plant, Yekaterinburg
PLC upgrade + IoT connectivity module for an 8-year-old roll forming line.
1.5%Waste
-60%Downtime
IoTMonitoring
🇲🇽 Mexico
Complete Tube Mill Line
Tube Manufacturer, Monterrey
Full tube mill from uncoiling to packaging. Square & rectangular tubes 20-100mm.
30+ t/dayOutput
2 shiftsOperation
RepeatOrder
🇮🇩 Indonesia
Custom Hat Section & Furring Line
Building Materials Supplier, Jakarta
Custom line for ceiling and drywall framing profiles with inline hole punching.
8 t/dayOutput
3 yrGovt Contract
38mmHat Height
🇵🇱 Poland
Pallet Racking Upright Line
Warehouse Racking Manufacturer, Warsaw
Precision roll former with 24 stations, servo hole punching, and laser measurement.
±0.3mmTolerance
24 stnForming
ISOCertified
🇧🇷 Brazil
Solar Mounting Bracket Line
Renewable Energy Components, Sao Paulo
Galvanized steel mounting rails and clamps for solar installations.
200K m/moRails
3 EPCsSupplied
HDGCompatible
🇹🇷 Turkey
UHSS Bumper Beam Line
Tier-2 Automotive Supplier, Bursa
High-strength steel forming for automotive crash structures. Passed PPAP Level 3.
UHSS800+ MPa
<0.5°Springback
PPAPL3 Pass
In-Depth Case Studies
Detailed project breakdowns showing challenges, solutions, and measurable results.
CZ Purlin Production Line - Saudi Arabia
Client: Steel fabrication company, RiyadhYear: 2023
Machine: Full CZ quick-change purlin line with auto stackingIndustry: Construction / Steel fabrication
Challenge
The client needed to replace imported European profiles with local production to reduce material costs by 30% and shorten lead times from 8 weeks to same-day delivery. Their existing manual fabrication process could not meet the growing demand from government infrastructure projects.
Solution
Unionindus supplied a fully automated CZ quick-change purlin line (80-300mm width range) with servo-driven flying cut-off, automatic stacking, and bundle wrapping system. The line included:
- 10-ton hydraulic decoiler with coil car
- 18 forming stations with Cr12MoV rollers (HRC 58-62)
- Servo flying cut-off (no stop, no deformation)
- Auto-stacking with 6-meter bundle length
- Siemens S7-1200 PLC with 10" touchscreen HMI
Implementation
45-day manufacturing + 10-day on-site installation and commissioning by 2 Unionindus engineers. Remote factory layout design was provided 2 weeks before shipment to ensure the facility was ready.
Results
Production capacity increased by 40%. Daily output reached 25 tons. Payback period achieved in 16 months. The client has since placed an order for a second roofing panel line.
Roofing Panel Production Line - Vietnam
Client: Roofing materials manufacturer, Ho Chi Minh CityYear: 2022
Machine: Double-layer roofing panel roll forming lineIndustry: Construction / Roofing
Challenge
The rapidly growing domestic construction market demanded a 50% capacity increase within 6 months. Existing manual roll forming lines could not meet quality consistency requirements, resulting in customer complaints about panel flatness and wave defects.
Solution
We supplied a double-layer roofing panel line (corrugated + trapezoidal profiles) with automatic decoiler, pre-shear, hydraulic cutting, and stacker. Key specifications:
| Parameter | Value |
|---|---|
| Forming Speed | 20 m/min |
| Effective Panel Width | 1,000 mm |
| Material Thickness | 0.3 - 0.8 mm (PPGI) |
| Cutting Tolerance | ±1 mm |
| Control System | Mitsubishi PLC + 7" HMI |
Implementation
Remote factory layout design + on-site installation (14 days) + operator training (5 days). Our engineer supervised the first 3 days of production to ensure quality parameters were met.
Results
ROI achieved in 18 months. Material waste reduced from 5% to <2%. Labor requirement reduced from 8 operators to 3. Zero quality complaints in the first 12 months of operation.
Industry 4.0 Retrofit - Russia
Client: Metal processing plant, YekaterinburgYear: 2023
Machine: PLC upgrade + IoT connectivity moduleIndustry: Manufacturing / Metal processing
Challenge
An existing 8-year-old roll forming line had outdated relay controls, frequent breakdowns, and no production data tracking. The client wanted to extend machine life rather than replace it, but needed modern monitoring capabilities to compete in a demanding market.
Solution
We retrofitted the existing line with a new Siemens PLC + HMI touchscreen, added an IoT connectivity module for remote monitoring, and supplied new roller sets for an additional profile range. The IoT module provides:
- Real-time speed, quantity, and status monitoring
- Alarm push notifications to mobile phones
- Production report generation (daily/weekly/monthly)
- Remote PLC access for diagnostics and parameter adjustment
Implementation
20-day retrofit completed by 1 senior Unionindus engineer. Remote support for PLC programming was provided throughout the commissioning phase. The client received a 2-day training session on the new HMI interface.
Results
Material waste reduced to 1.5%. Downtime reduced by 60%. Real-time production monitoring enabled via mobile app. The client avoided a $150,000+ new machine purchase while achieving comparable performance.
What Our Clients Say
Direct feedback from the factories running our machines every day.
Unionindus delivered the complete line ahead of schedule. Their engineer stayed for 12 days until our team could operate the machine independently. One year later, the line is still running at 95% uptime.
We compared machines from China, India, and Turkey. Unionindus offered the best balance of price, quality, and after-sales support. The 18-month ROI was exactly as they projected.
The IoT upgrade transformed our old line. We now receive alerts on our phones when production drops or a fault occurs. The remote diagnostics saved us two emergency service calls in the first 6 months.
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