What Happens After the Rollformer?
Choosing the Right Purlin Handling System for Modern Purlin Production
Modern purlin manufacturing is often judged by the speed of the rollforming line, the sophistication of the punching system, or the level of automation built into the machine. Yet one production stage is frequently overlooked—the handling process after the profile leaves the rollformer.
How finished sections are transferred, stacked, bundled, and prepared for shipment has a direct impact on labour requirements, production flow, safety, and overall manufacturing efficiency. Choosing the right rollforming outfeed system isn’t simply about moving profiles away from the machine; it’s about matching the handling process to your production volume, workforce, and future growth.
In this article, we look at the different levels of steel profile handling, from simple manual conveyors through to fully automated end-of-line systems, and how each solution supports modern rollforming automation.
The Final Stage of Every Rollforming Line
Every modern rollforming line follows a series of production stages, each contributing to the overall efficiency of the manufacturing process.
- Coil management and loading
- Strip preparation, including punching and shearing
- Rollforming and quality control
- Profile handling, stacking, bundling, and preparation for shipment
While much attention is given to the first three stages, the final stage often determines how efficiently production continues once the profile has been formed.
Handling downstream of the rollformer isn’t a single solution—it’s a progression. Manufacturers choose the level of automation that best matches their production volume, available labour, operational requirements, and investment budget.
Choosing the Right Level of Profile Handling
There is no single handling solution that fits every production environment.
Some manufacturers prioritize low initial investment, while others focus on reducing labour, increasing throughput, or preparing for future automation. The handling system should reflect those priorities.
Modern purlin handling systems can be viewed as a progression—starting with simple manual solutions and advancing toward fully automated end-of-line processing.
Level 1 – Roller-Top Support Conveyor
At the simplest end of the process is a roller-top support conveyor.
Once the profile exits the rollformer, it travels onto a roller conveyor where operators manually lift each finished purlin sideways into a bundle.
This is a straightforward and cost-effective solution for manufacturers with lower production volumes. However, because profile handling is performed entirely by operators, the production pace depends heavily on manual labour throughout the shift.
Typical characteristics
- Low initial investment
- Fully manual profile handling
- Suitable for lower production volumes
- Requires continuous operator involvement
Level 2 – Side Support Rail System
The next step introduces a side support rail system.
Instead of lifting each profile directly from the rollers, operators slide the finished section onto a dedicated staging area before stacking and bundling it manually. Completed bundles are then removed using a forklift or overhead crane.
While this improves operator handling and creates a more organized working area, the process still relies on manual labour, with two operators typically managing the outfeed throughout production.
Typical characteristics
- Improved profile staging and organization
- Easier manual handling
- Manual stacking and bundling
- Better workflow than a basic roller conveyor
Level 3 – Automatic Stacker Conveyor
As production volumes increase, manufacturers often move beyond manual handling and into automatic stacking systems.
At this stage, operators are no longer responsible for collecting profiles at the outfeed. Instead, the handling system automatically receives, positions, and stacks finished sections as they exit the rollformer.
Modern systems are designed to accommodate the full range of profile sizes, lengths, and section types produced by the line. The stacking sequence is also optimized based on the profile geometry.
For example:
- Cee sections are stacked with every second profile rotated and nested inside the previous one before bundling.
- Zee sections naturally nest together without rotation until the required bundle size is achieved.
This creates a completely automated profile handling process from the moment the profile leaves the rollformer.
Typical characteristics
- Fully automated profile stacking
- Handles multiple profile sizes and lengths
- Intelligent nesting based on profile type
- Eliminates manual collection at the outfeed
- Improves production consistency and labour efficiency
Level 4 – Integrated Bundling, Wrapping and Labelling Conveyor
Automatic stacking is often only the beginning of a fully integrated rollforming outfeed system.
Once the required bundle size has been reached, the production line can continue automatically with bundling, wrapping, labelling, and preparation for transport—without manual intervention.
Automatic bundling secures each stack before it moves to the next stage. Depending on the production requirements, the bundle can either pass through a stationary wrapping unit or remain stationary while a travelling wrapper applies straps at programmed intervals based on the product type, bundle dimensions, and length.
Completed bundles are then transferred to a designated unloading area, ready for forklift handling, storage, or shipment.
Additional automation options further improve downstream operations.
Centre-of-Gravity Marking automatically prints reference lines onto each completed bundle, allowing forklift operators and crane crews to identify the correct lifting position quickly and safely.
Automatic Labelling applies production and order information directly onto every finished bundle, improving traceability while eliminating manual labelling tasks.
Typical characteristics
- Automatic bundling
- Automatic wrapping
- Centre-of-gravity marking
- Automatic bundle labelling
- Ready for logistics and shipment
Build for Today's Production—Ready for Tomorrow's Growth
Not every manufacturer requires a fully automated handling system from day one.
For some operations, a simple roller-top conveyor provides the right balance between investment and production needs. Others may benefit from side support rails, automatic stacking, or a fully integrated handling cell with bundling, wrapping, and labelling.
The important point is that profile handling should evolve alongside production.
As output increases and labour demands change, manufacturers should be able to expand their handling capabilities without redesigning the entire production line. Starting with the right foundation makes future upgrades simpler, more cost-effective, and far less disruptive.
A well-designed purlin handling system isn’t just an accessory to the rollforming line—it becomes an essential part of long-term production efficiency.
Complete Rollforming Solutions from SFS International
At SFS International, we design and manufacture complete rollforming line solutions for the steel framing and purlin industries—from profile production through to downstream handling and automation.
Whether your operation requires a simple rollforming conveyor, an automated stacking system, or a fully integrated end-of-line solution with bundling, wrapping, and labelling, every configuration is matched to your production requirements, labour availability, and future growth plans.
Because efficient purlin manufacturing doesn’t end when the profile leaves the rollformer.
It continues through every stage of steel profile handling—until the finished bundle is ready for transport.
Looking for the right handling solution for your production line?
Our engineering team can help you configure the most suitable rollforming outfeed system based on your production volume, profile range, automation goals, and future expansion plans.
About Purlin Production Insights
Purlin Production Insights is SFS International’s technical article series exploring the engineering and technologies behind modern purlin manufacturing.