InnovatIve roll formIngGood total economy, reduced strain on the environ-ment, well-shaped design and lean production

“Better product, greater margIns”Prismaflex AB, Staffanstorp, Sweden

“eye-catchIng, stronger”Etac AB, Anderstorp, Sweden

“See the benefits of innovative roll forming!”

It is now a fact that roll forming is a rational and cost effective production process. What few people are aware of is the constant research being carried out to further push the boundaries of what is possible. Increasing market demands for good total economy, reduced strain on the environment, well-shaped design and lean pro-duction are challenges that drive us in our work with innovative roll forming. Because there are essential differences between roll forming and advanced roll forming - and we want our custo-mers to be aware of these.

Ortic and Bendiro both have their own research facilities as well as active participation in coordi-nated projects together with customers who share the same vision of the roll forming as we.

roll forming, more right than ever

“It feels that roll forming has come of age and that more and more people are realising the benefits of applying the technology to their products. The insight that weight savings and increased performance offer environmental benefits, while at the same time these criteria support financial incentives makes it easy to argue for our manufacturing process whatever the customer.”

laser welding, uhs and round technology

“We have focused for some time on market-ing advanced roll forming as a concept. And it has paid off. Enclosed welded profiles are now a part of everyday life. More and more of our customers are realising the benefits of using laser welded roll formed profiles made of high strength material. We have further improved our market position through successful imple-mentation of 2.5 D processing which produces rounder enclosed profiles.”

Be our guest. Knowhow on offer!

“It has a lot to do with knowhow and we at Bendiro are only more than glad to share. One way is to enrol in our Profile Technology School. This is a training course produced for our custo-mers and other interested parties wishing to acquire a basic knowledge about roll forming,

GOOD TOTAl EcOnOMy, rEDucED STrAIn On ThE EnvIrOnMEnT, WEll-ShAPED DESIGn AnD lEAn PrODucTIOn

ulf AnderssoncEO Bendiro Profile Tech AB

profIle technology school

but most of all it is for designers and product developers to begin planning on using roll forming from the start. All to achieve the best possible result and optimal end product. There is large interest for the school and we see it as a natural part in future collaboration with our customers.”

Bendiro + ortic = innovative roll forming

“For us to be able to produce advanced profiles, we require machines that can give us the oppor-tunity. Bendiro’s innovative product solutions, combined with the constant research that OrTIc represent, speaks for itself. It offers synergy effects that are directly beneficial to our customers. The major technology shift of the future, OrTIc’s patented 3D technology, is already a fact and it opens the door to creating shapes that were not previously possible.

Add then the uhS material, which was seen only a few years ago as being impossible to work with, and you have innovative roll forming that offers undreamed of opportunities, thanks to Bendiro.”

“We have exciting times ahead! Join us on our journey!”

ulf Andersson

Enrol now!www.bendiro.se

“We got a better product with greater margins”

Prismaflex produces scrolling signs for differ-ent advertising messages. These signs contain triangular profiles that rotate constantly to continually alternate the message in the actual poster display area. These profiles are now manufactured by Bendiro Profile Tech.

anders Janson, r&d manager, prismaflex aB, sweden

“From the outset, we manufactured these trian-gular profiles in aluminum, but the prisms con-stitute a major share of the value in the signs and we went looking for a more cost effective alternative.

PrISMAFlEX AB, STAFFAnSTOrP, SWEDEn

prIsmaflex aB

using roll formed steel, we had access to a material that was just as durable with the increased strength, and which could be formed within sufficient narrow tolerance levels. These aspects are significant as our signs are more often than not exposed to the elements.”

roll forming came into its own

“Previously, we have looked at the option of roll forming our profiles, but for different reasons, this has not suited the character of our pro-duct. Everything fell into place with this project. It was about large volumes of one and the same product, and as a result, we were able to make maximum use of what roll forming has to offer.”

simplification led to improvement

“We have previously had discussions with Bendiro and when this project started, we began by presenting them with a basic concept. They brought much valuable expertise to the table, not in the least in how to customise manufac-turing of our product. We appreciated the fact that they presented a simplified version of the profile to better suit the roll forming process. This simplification was also an improvement as we got more complexity with fewer processing stages.”

“We now get completely welded profiles where perforation is also integrated in the forming process which prevents any costly and time-consuming post production processing.”

valuable effects

“By changing the production process and mate-rial, we have been able to reduce the weight of our profiles as steel is a stronger material than aluminum. This in turn leads to less mainte-nance and service of our advertising signs.

Altogether this gives us both a better product and significantly better margins.”

“roll forming is not ideal in all situations but in this project we have, on the whole, only reaped the benefits. It places however greater de-mands on us when it comes to planning orders. One does not start the production process just for small series.”

close by and flexibility

“cooperation with our subcontractors has to work well. Functional and flexible cooperation is also reflected in the margins. Bendiro is an ideal supplier for us at Prismaflex. They are large enough, they are located close by and are flexible and easy to deal with. These are impor-tant criteria for us.”

“When required, roll forming and Bendiro will therefore go hand in hand with the development of our products.”

facts

Prismaflex is a global market player that designs, manufactures and sells different types of outdoor advertising solutions. The company has 10 subsidiaries world-wide and turns over approx. € 70 M. Prismaflex has more than 45,000 signs posted in 120 different countries and has an annual printing capacity of 3 million square metres with 30 printing machines. Prismaflex AB is located in Staffanstorp, Sweden.

KlIppan-safety aB

Klippan-Safety AB is a system partner for the international automotive industry. The company is Europe’s leading developer and manufacturer of complete bed systems with integrated occu-pant restraint systems for trucks. When Klippan-Safety AB in Klippan was in the process of manufacturing a new bed system for Scania’s trucks, the only choice was roll formed profiles from Bendiro.

Bengt hallberg, purchasing and logistics manager at Klippan-safety aB

“In this project, we are using a new bed system called Flex Frame. As the name implies, it is a flexible system that is built up using holders in the form of a frame for which the customer can then select a bed that suits them.”

tougher demands, lighter vehicles

“At Klippan-Safety, we have previously used most types of manufacturing, but regards this project, there were many aspects that made roll forming the best solution. We place great demands on guaranteeing safety and mechanical strength. The profile also contains many characteristics, with which we wished to achieve a form of lean production, with as little post production processing as possible. With encouragement from the automotive industry, it is our aim at all times to reduce the weight of our products.”

more than 25 steps to the finished profile

“The result was a roll formed galvanised profile that was formed in more than 25 steps. using inbuilt laser welding and a punched perforation pattern. These profiles are then cut to fix exact

lengtht, that are then bent to create a bed frame. It is also important that there are no sharp edges on the profile as these can ruin mattresses and mattress fabrics. It is a flexibly rigid and strong lightweight design with minimal post production processing, just as we asked for.”

Willing to invest

“roll forming requires expertise and experience. As a customer, we must be able to trust our supplier to provide these. Bendiro has more than met with our expectations. Above all, they have proven to be very flexible yet also attentive and willing to invest, which is well exemplified by their inbuilt laser welding system. They are also the right sized company. Enough capacity to go around but not too big. roll forming is definitely something we will continue to work with in the ongoing development of our products.”

“We received a lightweight design with minimal post production processing”

KlIPPAn-SAFETy AB, SWEDEn

facts

Klippan-Safety is a company of note that was founded way back in 1877. Today, the company is a system partner for the international automotive industry offering unique expertise in the fields of safety and comfort. The production of bed systems is supplemented by the development and manufacture of safety nets and seat belts. Klippan-Safety employs around 250 employees and has operations in Sweden, Germany, Poland and Brazil.

etac aB

“The profile looks better, is more durable and gives us better total economy”

ETAc ABSWEDEn

Etac AB is an expansive company that offers products to people with reduced mobility as well as a range of hospital and nursing home pro-ducts. The product range includes an extensive range of wheelchairs. Among these you will find the Etac M 100, a wheelchair for which Bendiro has manufactured an advanced armrest profile that is not only strong but also pleasing to the eye.

daniel Johansson, product developer/designer at etac aB

“We have previously manufactured this armrest using extruded aluminum. But with the approach-ing En standard in unison with our own increas-ing demands, we chose to find a more long-term solution. Within the health care sector, one can see a clear trend where users and patients are getting heavier and larger, and in many cases current designs are not able to cope.”“This is the first time we are using a roll formed profile in this manner. It has been an exciting process as it is an advanced profile with many features that have to work together. We came in touch with Bendiro through another supplier and have come up with a fully functional solu-tion in close collaboration with them. We had to rework the first prototype somewhat regard-ing certain parts so that the profile could be adapted to the forming process, but this did not affect the final product in any way. On the contrary.”

appealing designs sell more

“By thinking smart from the outset in the design stage, it is much easier when the profile goes into production later on. All processing today occurs in the machine and a ready designed product is made directly including perforation patterns and laser welding. It is also an appeal-ing profile which suits us at Etac as we see good design at all times as an important part of the whole concept.”

uhss delivers

“We have chosen ultra high strength steel to guarantee durability but also to have a light-weight profile. Besides now having a more dura-ble and appealing profile, we have also been able to reduce costs due to reduced post production processing. This is a wheelchair we strongly believe in and in this respect, we have to get all the components right. Even seen from a financial perspective.”

a knowledge bank is a good investment

“Bendiro has been a knowledge bank for us and we will definitely make use of it in future projects. Knowledge is always worth investing in. But, roll forming requires volumes and not every wheelchair are cut out for this method of manu-facturing. We now have to roll out the M100 in the market first. This is very exciting!”

facts

Since setting up in 1972, Etac has expan-ded to become one of Sweden’s leading players in the home health care market. The company operates in Sweden, norway, Denmark, England and Germany. Products are sold to many parts of the world through distribution partners. The group employs in total 650 employ-ees and has a turnover of SEK 1 billion.

construction

Functional profiles, often longer profiles (>2,5 m) and pre-coated, preferably with a slightly thinner material (<1 mm). cost efficiency is an important argu-ment; others are levels of service and flexibility, most often not directly load-bearing constructions which is why thinner material thickness is used.

IndustryOur ”other area” – everything from rotation filters within the pulp industry, via roof tiling factories to industrial gates, shelving and equipment cabinets for the telecommunication sector. The profiles may often be manufactured using other techniques, but when the volumes are large enough, roll forming offers better return on investment.

InteriorsShop interiors, load bearing profiles and designed functional profiles for the furniture industry. Often with greater demands on finish, thicker materials (1.5 – 2.5 mm) used in load bearing profiles. rather advanced perforation patterns, more and more focus on high strength materials and welded pro-files. large volume flexibility is required of us.

Automotive

load bearing profiles, often in high strength materials with high demands on finish and quality. large focus within the automotive industry to increase use of roll formed profiles as they open the way to reducing weight by using high strength materials that are impossible to press but can be roll formed.

Bendiro’s profiles work everywhere!Bendiro’s profiles are constantly being used in new applications, but the following are the main areas we work in:

BEnDIrO PrOFIlE TEch AB · Kvekatorpsvägen 26SE-311 32 Falkenberg · SWEDEnPhone: + 46 (0) 346 - 71 43 40 · E-mail: info@bendiro.se · www.bendiro.se