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Model NO. : SW-Step Beam Line

Full Automatic Box Beam Roll Forming Line

The Box beam roll forming machine is precision-engineered to produce high-strength beams for upright rack systems, supporting both two-piece seamed and one-piece direct forming methods. This fully automated line integrates uncoiling, roll forming, welding, and stacking to maximize efficiency and reduce labor costs. Featuring a robust gearbox drive system and advanced controls, the machine produces various beam sizes with thicknesses from 1.5mm to 3.0mm. Tailored to your specific drawings and tolerances, our equipment ensures the production of perfectly functional, high-performance profiles for your pallet racking requirements.
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Product Description
SUNWAY Full Automatic Box Beam Roll Forming Line featuring integrated online welding and auto stacking system

The box beam roll forming machines developed by SUNWAY are specifically engineered to produce high-strength beams for heavy-duty racking systems. In the current market, there are normally two production methods for these profiles: 1) two C-beams are first formed on a high-precision roll forming machine and then seamed in a combined unit to create a box beam; 2) one beam is formed directly on a single roll forming machine to achieve the final box profile.

Our box beam roll forming line is a high-performance, full-automatic solution. It is specially designed and equipped with automatic welding and stacking systems, which significantly reduce labor costs and increase production efficiency. As a leading supplier, we ensure every box beam roll forming line is tested for maximum durability.

The whole line flow chart of this box beam roll forming line includes: Electric uncoiling — Feed guiding and leveling — Roll forming machine (gearbox drive system) — Fly cutting — Automatic conveying and turning table — Boxing machine (gearbox drive system) — Output table — Auto welding and stacking.

This intelligent roll forming machine can handle various beam sizes with a thickness range of 1.5–3.0mm. Processes such as uncoiling, feeding, forming, welding, and cutting are all automatically realized on one seamless line. In addition to these box beam roll forming machines, we provide specialized machinery for step beams, upright racks, and shelf boards—all essential components of a complete pallet racking system.

At Wuxi Sunway Machinery Co., Ltd., we manufacture a comprehensive range of equipment for warehouse pallet racking systems. We provide tailored solutions based on your specific drawings and budget, offering professional one-to-one service. Whichever box beam roll forming machines you choose, the quality of SUNWAY Machinery ensures you obtain perfectly functional profiles for your storage business. Whether you need a single roll forming machine or a complete production line, we are here to support your growth.

Profile Drawings
Technical profile drawings and 3D assembly diagram of SUNWAY Box Beams
Finished galvanized box beams produced by SUNWAY machine, showing stiffening ribs and interlocking seamsFinished galvanized box beams with end connectors welded by SUNWAY automatic production lineClose-up detail of welded end connectors on galvanized box beams showing precise and strong weld seams
Production Line
Factory layout drawing of Automatic Box Beam Line showing uncoiler, roll forming, overturning, seaming, and automatic stacking systems
Product Details
Heavy-duty Hydraulic Uncoiler equipped with Coil Loading Car and Press Arm for automatic coil handling
Heavy-Duty Hydraulic Uncoiler
Precision Guiding, Leveling, and Feeding unit entering a heavy-duty roll forming line with gearbox transmission
Guiding, Leveling & Feeding Unit
High-speed P-beam roll forming line for warehouse racking system with PLC control
Roll Forming Machine
Servo-controlled tracking cutting system on Step Beam Roll Forming Machine for non-stop production
Servo Tracking Cutting
Automatic convey table and pneumatic overturning system for Step Beam Roll Forming Line
Convey Table & Overturning
Boxing and seaming station of Step Beam Roll Forming Machine driven by heavy-duty gearboxes
Boxing Forming
Automatic roller conveyor system transporting rack beams to the robotic welding station
Automatic Conveyor
Robotic welding and stacking station featuring industrial robot arm and welding power sources
Automatic Welding & Stacking Machine
Product Parameters
Automatic Box Beam Roll Forming Line
Machinable Material
A) Galvanized Coil
B) Cold/Hot-rolled Steel
C) Carbon Steel
Thickness(MM): 1.5-3.0 as per customer
Yield Strength250 - 350 Mpa
Tensil Stress350 Mpa-500 Mpa
Nominal Forming Speed(M/Min)10-20*Or According To Your Requirment
Forming Station18-20*According To Your Profile Drawings
DecoilerManual Decoiler*Hydraulic Decoiler (Optional)
Driving SystemChain Drive*Gearbox Drive (Optional)
Machine StructureSteel Plates Welded*Cast Iron Stands (Optional)
Rollers’ MaterialGCr 15*Cr12Mov (Optional)
Cutting SystemHydraulic Cut*Saw Cut (Optional)
Boxing UnitBy Chain*By Gearbox (Optional)
Welding EfficiencySpecification 50*100≥25 seconds/pcs, 
Specification 50*120-140≥30 seconds/pcs, 
Specification 50*160≥35 seconds/pcs (Except for beams with unilateral error of >1.5mm)
Welding & Stacking ProcessStack the hanging pieces in order on the automatic hanging piece feeding platform, then input the signal, the machine starts to automatically load the hanging pieces, and at the same time, the robot automatically grabs the crossbeam to the specified position of the machine platform, starts welding, first welds the two sides, rotates 90 degrees and then welds the two sides to complete
the welding, rotates to another station, and the robot takes the material to the finished product stacking, and the robot takes the material again, and the above actions are repeated. All the above actions are controlled and operated by the dedicated system for the crossbeam automatic line
Machine ColorIndustrial Blue*Or According To Your Requirment
Application

Box Beams in Heavy-Duty Racking Systems

The warehouse systems shown below highlight the essential role of high-strength box beams in modern logistics. Every beam you see in these images is a direct result of the precision engineering provided by our box beam roll forming line. As a critical horizontal component, the box beam must withstand immense pressure, and our box beam roll forming machines are designed to ensure that the welding and structural integrity of each profile meet international safety standards.

In these large-scale storage facilities, the consistency of the profiles is key. Each roll forming machine integrated into our full-automatic line utilizes advanced technology to maintain strict tolerances. By choosing a SUNWAY box beam roll forming line, you are investing in equipment that translates directly into the high-quality, high-capacity racking systems displayed here.

Our commitment as a professional manufacturer is to provide a roll forming machine solution that is both efficient and reliable. These real-world applications demonstrate why global clients trust our box beam roll forming machines to build their warehouse infrastructure. Whether you need a standalone roll forming machine or a complete box beam roll forming line, SUNWAY ensures your finished products look and perform exactly like the professional systems in these photos.

Warehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machineWarehouse storage rack system project produced by SUNWAY upright roll forming machine

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Industry Solutions

As a global leader in high-precision engineering, SUNWAY provides comprehensive production solutions tailored for the modern logistics and industrial storage sectors. Our integrated suite of roll forming equipment—covering everything from upright frames and heavy-duty beams to essential bracing sections—is designed to create a seamless manufacturing ecosystem. By aligning our advanced technology with your specific project requirements, we help you transition from raw material to a complete, high-performance racking system with maximum efficiency and technical accuracy.

Heavy-Duty Industrial Warehousing

Our integrated production lines for upright racks and box beams provide the structural integrity required for high-capacity industrial environments. These solutions are engineered to ensure maximum load-bearing safety while optimizing vertical space for high-density pallet storage.

Retail & Commercial Display Systems

By combining box plate and step beam roll forming technology, we deliver specialized solutions for the retail sector. These lines produce high-finish, adaptable shelving panels and beams that are perfect for supermarket displays and commercial storage where aesthetic precision and durability are equally vital.

Seismic-Resistant Logistics Infrastructure

We offer specialized configurations incorporating C bracing and upright sections to build stable, seismic-resistant racking structures for global logistics centers. Our machines provide the tight tolerances needed to ensure every component fits perfectly, enhancing the overall stability of the racking grid.

Automated Turnkey Production Projects

Beyond individual machinery, we provide fully automated "one-stop" production workflows that cover the entire process from uncoiling to precision welding and cutting. We work one-to-one with clients to develop bespoke systems that meet specific budget, drawing, and volume requirements for large-scale manufacturing.

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