Understanding the Energy Consumption of Roll Forming Machines

How much energy does a roll forming machine consume? This guide will help steel framing businesses understand the cost of energy for operating a roll forming machine. When starting or expanding a steel framing business, one of the most common questions is how much energy consumption to expect from roll forming machines. The roll forming process is known for its efficiency and low waste, but understanding the electricity requirements helps owners plan their operational budgets accurately.

In this article, we’ll explore how to calculate the energy consumption of various roll forming machines, how this impacts the operating cost of a steel framing business, and what to expect from real-world examples of the roll forming process in action.

Energy Consumption Basics for Roll Forming Machines

Every roll forming machine has an average current draw (flow rate) and operates on a specific voltage. These two numbers determine the energy consumption per hour, which can be calculated using the simple formula:

Consumption (Watts) = Flow Rate (A) × Voltage (V)

This calculation gives you the hourly electrical draw of your roll forming machines and helps estimate daily and annual energy usage. Because the roll forming process often involves continuous production, even small efficiencies in energy consumption can make a noticeable difference in the long-term performance and cost profile of a steel framing business.

Sample Calculation for a Steel Framing Business

Let’s look at a realistic scenario for a new steel framing business in Chicago, IL, USA, operating four roll forming machines: the Scotpanel 7090, Scotpanel 5140, Scottruss 6050, and KFS Framemaker 1420.

Scotpanel 7090 and Scotpanel 5140 each have an average flow rate of 8A at 230V.

Scottruss 6050 runs at 415V with a flow rate of 8A.

KFS Framemaker 1420 operates at 48A and 460V (full system load).

Now, let’s apply the roll forming process energy consumption formula:

Consumption = 230 × 18 + 230 × 18 + 415 × 8 = 11,600W (or 11.6 kW)

If these three roll forming machines run for eight hours a day, the energy consumption totals 92.8 kWh per day.

For the KFS Framemaker 1420, the daily roll forming process load is 8 × 48 × 460 / 1000 = 176.64 kWh.

Adding everything up, the total energy consumption for all four roll forming machines in one workday is 269.44 kWh.

Calculating Daily and Annual Energy Costs

In Chicago, ComEd’s rate is approximately $0.098 per kWh, while the national average sits closer to $0.175 per kWh. Using the local rate, the total cost of running all roll forming machines simultaneously for eight hours a day would be:

269.44 kWh × $0.098 = $26.40 per day.

Over 260 working days per year, the steel framing business would spend roughly $6,864 annually on electricity. For the production capacity and precision that the roll forming process delivers, this energy consumption cost is surprisingly modest and just a fraction of the overall operating expenses.

Why Energy Efficiency Matters in the Roll Forming Process

The roll forming process inherently promotes energy efficiency. Compared to other metal fabrication methods, roll forming machines operate continuously and with minimal waste. There’s little downtime, almost zero material loss, and the electric motors are optimized for consistent torque rather than short bursts of high energy.

This steady-state operation not only reduces energy consumption but also extends machine life and lowers maintenance costs, both critical factors in running a profitable steel framing business.

When evaluating which roll forming machines to invest in, always check the manufacturer’s literature for average flow rate and power requirements. Scottsdale Construction Systems, for example, includes detailed energy and performance data for every model, ensuring your steel framing business can make accurate cost projections.

The Real Cost of Energy for Roll Forming Machines

When considering roll forming machines, the question of energy consumption often seems daunting. However, as shown in this sample calculation, even operating multiple roll forming machines daily leads to surprisingly low energy costs relative to total production output.

For any steel framing business, understanding and planning for energy consumption is essential, but the numbers show that the efficiency of modern roll forming machines keeps this expense well within reason. As your steel framing business scales, optimizing production schedules and machine usage can further reduce the energy footprint of your roll forming process, delivering both sustainability and savings.

Additional Scottsdale Roll Forming Solutions and Resources

1. Blog – How to Launch a Successful Steel Framing Business
2. Blog – Ultimate Guide to Steel Framing Manufacturing Shop and Floorplan
3. Blog – Power Source Options in Advanced Roll Forming Technology
4. Blog – Empowering New Steel Framing Businesses: From Startup to Success
5. Blog – Expert Tips for Successfully Operating a Roll Forming Business
6. Blog – The Best Data-Driven Roll Forming Technology for Steel Framing Production
7. Blog – Reasons to Invest in a Multi-Profile Roll Forming Machine
8. Blog – Growing Your Competitive Edge with In-House CFS Fabrication
9. Video – How Scottsdale’s Roll Forming Technology and Software Support Business Growth
10. Financial Services

To learn more about Scottsdale’s roll forming solutions and steel framing ecosystem, visit us at www.scottsdalesteelframes.com, call us at +1 (888) 406-2080, or email us at rollformers@scottsdalesteelframes.info.