DALLAN by MMBF Agenzia Pubblicitaria

HISTORY

INNOVATION AND SPECIALISATION

ROLL FORMING

MACHINES AND SYSTEMS

TECHNOLOGY

SOFTWARE

SERVICES

PRODUCTION SYSTEMS

PLASTERBOARD

T-BAR AND SUSPENDED CEILINGS

ROLLER SHUTTERS

VENETIAN BLINDS

SPECIALS

HISTORY

Established in 1978 by the engineer Sergio Dallan, the company started out as a design and engineering office focussing on rollers for cold rolling mills. Just a few years later the company produced its first roll forming machines and the international market became an important outlet. Dallanâ&#x20AC;&#x2122;s initial decision to specialise in light gauge materials meant it could refine the machining of particularly delicate materials used in interior finishes and sun shading sectors. Based on the values of its founder and a service geared to customer needs, the company has continuously grown together with its partners: From the first simple lines for suspended ceilings it now manufactures production and packing systems for T-bars, roller shutters, Venetian blinds, special profiles as well as a whole range of punching and laser-cutting machines.

Watch the videos!

In 1978 Sergio Dallan set up the firm “Dallan Ing. Sergio” In 1982 Sergio Dallan took the decision to focus on machines for making thin-walled profiles and in 1984 opened up to the international market.

1978

In 1988 Dalcos was formed: a company specialised in the manufacture of coil punching machines and sheet metal pre-processing systems for subsequent roll forming, panel making and bending.

19 82

19 96

19 93

In 1993 Simeoni srl was established initially to produce forming rollers for Dallan, specialising thereafter in the manufacture of dies and precision machining.

1 0 20 20 1 3 Dallan Spa was formed from a merger of the various group companies, thereby consolidating its wealth of technology and know-how.

In 1996 Elda srl was established to produce automation systems and software.

In 2001 Ada srl was established to create assembly and packaging systems for profiles manufactured by our machines.

INNOVATION AND SPECIALISATION For 40 years Dallan Spa has been developing, constructing and selling complete manufacturing systems and solutions for sheet metal working from steel coil: roll formers, punching machines, laser cutting and packing machines. Quality and the attitude for innovation have always been key features of Dallan working method. With more than 7000 profiles and more than 3000 plants installed all over the world, the company has exceptional experience in machining light gauge sheet metal and top quality products for interior finishes, sun shading, air treatment, metal furniture, lighting, agriculture, breeding and energy sectors.

Over the years the companyâ&#x20AC;&#x2122;s strong spirit of innovation has consolidated the whole production chain and developed high-performance systems that enable its customers to compete in the top market brands. With more than 100 patents to its credit and boasting a team of 150 professionals, Dallan currently develops and manages in-house various technological aspects such as the production of the forming rollers and dies, the development of software to use in its plants, the design of automation devices for product packing as well as all strategic activities to ensure constant top quality profiles and packing.

ROLL FORMING Roll forming is a machining process in which a flat metal strip is progressively transformed into a finished part or profile whose length can vary. The transformation takes place by passing the material through powered tandem sets of rollers, which step by step give the metal strip the shape of the finished profile. The care and attention that Dallan takes over the design and construction of components results in high precision roll formers, which are suitable for processing light gauge and delicate materials and successfully produce even the most complex profiles. The high level of specialisation acquired over 40 years means that Dallan offers it customers not only production systems and plants, but also its know-how with regard to product design and production cycle management, including the preselection of raw material suppliers.

DALLAN ROLL FORMERS Dallan offers a complete range of precision roll forming machines suitable for all types of production requirements. Designed and engineered for maximum efficiency and reliability, each roll former is made with precision and top quality materials, which guarantee the manufacture of excellent products thanks to precise controls and exceptional simplicity of use â&#x20AC;&#x201C; all features that have made the Dallan standard a benchmark in the world market.

T4 DALLAN T4 roll formers have been studied for machining the thinnest materials, starting from 0.2 mm thick. The first roll forming machines made by Dallan are still today used in the manufacture of roller shutters, profiles for drywall construction, profiles for suspended ceilings and T-bars, external Venetian blinds, insect screens and in many other sectors. Depending on the complexity of the profile, the T4 range can be fitted with between 4 and 50 roll stations and reach production speeds from 30 up to 160 m/min.

T5 DALLAN T5 roll formers are used to machine materials of medium thickness, up to 2mm thick. The machines are larger than the T4 models since they have an oversized sturdy structure designed not only to withstand greater stress, but also ensure a longer life as well as great precision, which is a hallmark of all Dallan machines. The main uses for this type of roll former include the production of metal shelving and furniture, building profiles, frames for fire and reinforced doors, profiles for fencing and vineyard poles, as well as gratings.

T6 DALLAN T6 roll forming machines is the eavy duty range for machining the thickest materials, up to 3mm thick, and with the greatest bend height. These machines have a structural design that ensures a strengthened structure, given the applications involving very thick materials or high-strength special alloys.

MACHINES AND SYSTEMS Integrata In response to just-in-time production needs Dallan has developed the range of INTEGRATA roll formers, whereby a single machine produces the finished product including all the necessary processes of punching, shaping, cutting and bending. Examples of applications of these machines can be found in the manufacture of profiles for ventilation and air conditioning, for lighting fixtures, metal furniture and building profiles. Duplex The DALLAN DUPLEX flexible roll forming machines are available in two versions D4 and D5, designed to process different materials and profiles of differing thickness and widths thanks to their moving, opposing toolheads. They are most commonly used in the manufacture of profiles for suspended ceilings, faĂ§ades, profiles for roller shutter and Venetian blind boxes and for building profiles.

DALCOS Punching machines and Laser cutting machines Dalcos is the Dallan division that has been specialising for over thirty years in the construction of coil-fed punching and laser cutting systems. The development of coil processing technologies has enabled Dallan to supply highly efficient in-line production systems with up to 100% optimisation of the material. The Dalcos brand currently offers 4 lines of production systems designed to satisfy the widest range of production applications. PXN line comprises hydraulically operated punching systems: available in various configurations, they may be fully customised making them suitable for processing coils with widths from 20 up to 1500 mm and thickness up to 4 mm. EXN range offers coil-fed punching systems with servo-electric actuators, which guarantee high performance and maximum energy efficiency. LXN laser cutting systems embody all the technological expertise of Dalcos with their flexibility, precision and exclusive vision system making them suitable to process either coils or standard size sheets. Lastly, ELXN combo systems combine the power and performance of electric punching with the flexibility and efficiency of fibre laser cutting, achieving double the output compared to traditional systems.

Roll forming lines Dallan has developed various production systems to meet differing market requirements. The simple and compact DALLAN EASY roll forming lines are suitable for firms wishing to make Dallan quality products without heavy investment. For high performance levels Dallan has developed professional integrated production systems complete with automated assembly and packing of the profiles. Depending on the application, these systems come with the exclusive Dallan COIL TO WINDOW (roller shutters, Venetian blinds) or COIL TO PACKAGE (T-bars, plasterboard) technologies, which cover the whole production process starting from the raw material through to the finished and packaged product. In the roller shutter and Venetian blind sector, Dallan has created stand-alone automated systems for the application of accessories, assembly of the products and packaging, which can be placed alongside or applied in-line to existing production systems.

TECHNOLOGY Continuous innovation and development of technologies and production processes is a fundamental part of Dallan philosophy. The process starts with the meticulous design of the profile, working alongside the customer, and then creating the most suitable production system for the relative production requirements to ensure constant maximum efficiency, output and precision. Developing more than 7000 profiles for various market sectors, Dallan has incorporated many exclusive technologies with the aim of making its systems easier and easier to use.

DallanÂŽ | COMBI

Dallan has been using the exclusive COMBI technology for more than thirty years to achieve fast production changeover, exploiting a cassette system in which the forming toolhead includes the gearing, drive shafts and accessories for machining the profile. A roll forming line may have more than one COMBI system, each one dedicated to a particular profile. A COMBI can be changed very quickly thanks to the precise positioning solutions halving set-up machine and making the whole line suitable for just-intime manufacture. COMBI technology is not only applied to toolheads but also to fast die changeover, making the production system even more efficient.

LEAN philosophy

Dallan® | NONIUS

Control over the entire production cycle

All Dallan production systems are designed in accordance with LEAN manufacturing philosophy and adopt cutting-edge technological solutions for easy-to-use and highly efficient production lines. Minimum levels of work in progress are therefore ensured and raw material waste is reduced thanks to coilfed machining which uses 100% of the material. In line with these principles Dallan production systems are especially suited to working environments requiring just-in-time manufacture, where production volumes have to be satisfied as the orders arrive; these systems offer customers excellent performance in terms of speed and flexibility.

Simplicity of use has always been one of the guiding principles for Dallan designers in developing production systems which deliver constant improvements in man-machine interaction. The exclusive NONIUS adjustment system makes machine adjustments as easy as possible, even for inexperienced personnel. Micrometric adjustments can be made quickly and easily to equipment setup with the possibility to return at any time to the basic set-up established during the final test and inspection by Dallan specialised personnel.

To guarantee the very high quality standard of both systems and products, Dallan makes most of the roll forming equipment and components in-house to ensure control over the entire production chain; this includes the selection of the best raw materials and the supervision of all the production processes through to installation on the machine. This work philosophy leads to the continual development of technological components which have an effect on final product quality, with the result that Dallan’s customers can be sure of having top quality products and long-lasting, high performance equipment and tools to consolidate their position in the market.

SOFTWARE

Dallan knows that the software installed in its systems is crucial for fully exploiting the advanced technical solutions and for simplifying the control of even very large plants. That is why Dallan has created an in-house department with a team of engineers specialised in designing and developing the software platform, which is then customised according to the different plants and specific projects. In line with Dallan philosophy, here too the creation process (from the selection of the electronic components to the system development and user interface definition) is managed internally to develop better cognitive ergonomics and ensure simple and intuitive man-machine interaction. In accordance with Industry 4.0 principles, Dallan also develops the production planning software for managing and monitoring the whole production system from the office, whatever the number of lines, achieved by exchanging information with the customerâ&#x20AC;&#x2122;s ERP platforms.

Dallan® | TOUCH The new Dallan | TOUCH interface makes production lines incredibly easy to use, when involving only one machine as well as when involving a complete system. Thanks to the advanced and intuitive graphics the alphanumerical controls are reduced, giving way to icons and ‘self-explanatory’ graphic elements. A single interface may be used in the integrated production systems to control data relating to the finished product and the packaging parameters. Industry 4.0 Dallan offers customers the expertise to support them in developing systems that implement an Industry 4.0 strategy.

SERVICES Since customer service leads to a successful project or design, Dallan constantly works to improve this function providing highly qualified support in all project and design management steps. The preliminary advice service offered by Dallan specialists is essential during the initial stages of study and design of a top quality product. Upon completion of the system or plant, the final test and inspection and commissioning carried out by specialised technicians ensure excellent results.

Final test and inspection at Dallan premises

Every system and product is tested in Dallan premises prior to shipment to check the quality of the product and the performance of the production system. Operators are also given a first training session, which prepares them for using the machine and reducing final installation times.

Dallan remote service

Safety

Dallan offers an efficient remote service for its systems, providing precise diagnoses on the state of the system and, if necessary, carrying out remote operations on the software. Precise and quick technical solutions are guaranteed by this service thanks to efficient spare parts management and on-site servicing, rendered by more than 40 specialized engineers.

The concept of safety is part and parcel of Dallan standards and so continual investments have been made over the years to improve machine safety with cutting-edge technical solutions and software, in line with relevant legislation in more than 80 countries all over the world.

PRODUCTION SYSTEMS

Plasterboard

T-bars

Roller shutters

Venetian blinds

Special elements

PLASTERBOARD SYSTEMS

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Dallan has developed a complete range of machines and systems for the manufacture of top quality profiles for drywall constructions. These are U- and C-shaped profiles provide support as tracks and studs for plasterboard panels in drywall construction and are also used as ceiling profiles. The profiles must be strong and fully suited for the purpose to guarantee high quality, sturdy constructions: the different profiles must in fact complete each other perfectly to form a solid framework.

D4 range of roll formers and automation systems for the manufacture of plasterboard profiles is designed to Dallan standards to produce functional profiles that are compatible with other structural elements. Various production solutions are available with different features regarding modularity and automation. This range starts with the lines with output up to 30 m/min, while systems complete with packing are used for very high output rates with maximum productivity up to 120 m/min. D4 range machines includes many exclusive Dallan technologies for fast adjustments and fast production changeover, so that the required profiles may be made even on just one line.

DALLAN D4: VERSATILE SOLUTIONS, MAXIMUM QUALITY AND OUTPUT Available versions Roll former

Product

Max. production speed

Machinable gauges

Machinable widths

Compatibility

Stud, track, ceilings

30 m/min

0.3-0.8mm

30-150mm

XST, A7

D4V

Stud, track, ceilings

60 m/min

0.3-0.8mm *

30-150mm

XST, A7, A10

D4V82

Stud, track, ceilings

120m/min

0.3-0.8mm *

30-150mm

XST, A10, A12W

DUPLEX

Stud, track, ceilings

120m/min

0.3-0.8mm

variable

XST, A10, A12W

D4X MACHINING

XST

Rotary deep drawing system

D4, D4V, D4V82

AUTOMATION SYSTEMS

Semi-automatic packing system

A10

Automatic packaging system

D4, D4V, D4V82

A12W

Strapping system for big bundles, with or without insertion of wooden bearers or battens

D4, D4V, D4V82

D4, D4V

COMPLEMENTARY ITEMS

D414

Accessories

40-60 pcs/min

D1V

Perforated angle beads

55 m/min

D4U

UA profiles up to 2mm

25 m/min

D4J

SIGMA, OMEGA, C, Z up to 3mm

20 m/min

* possibility of machining up to thickness of 1.5mm with reduced speed

SYSTEMS FOR T-BAR & SUSPENDED CEILINGS Watch the videos!

T-bar is a highly technical profile which, suitably joined to other components, acts as support for suspended ceiling panels. T-bar profiles are manufactured in various sizes but consist mainly of two types: Cross Tee and Main Runner. The profiles are machined to be easily fastened to the ceiling and each other to form a suspended framework supporting the ceiling panels. In more than thirty years Dallan has not only developed production systems for T-bar profiles, but also cooperated with the customers in designing the profile and deciding the features it should have. In fact Dallan has several patents in this specific sector. The profiles are sized and designed to customer requirements with different technical and aesthetic solutions, with alloy or integral hooks, different heights depending on the required load-bearing capacity and decorations obtained through an innovative in-line printing system.

With the D5 range Dallan offers all possible solutions for the manufacture of various types of T-bar profile with specific characteristics according to the production rate and speed of the automation system. As in all Dallan applications simple production systems are available as well as high performance fully automated lines complete with profile packing systems for large production batches.

DALLAN D5: PERFECT PROFILES AND CUSTOMISED PERFORMANCE

Available versions Roll former

Product

Combined production speed *

Machinable Thickness

Hook type

D54

Cross T and Main Runner

10 m/min

0.2-0.6mm

Integral hook

D57

Cross T

31m/min

0.2-0.6mm

Integral hook

D58D

Cross T

32 m/min

0.2-0.6mm

Alloy hook

D59D

Main runner

34 m/min

0.2-0.6mm

Integral hook

D51

Cross T and Main Runner

30 m/min

0.2-0.6mm

Integral hook

Compatibility

AUTOMATION SYSTEMS

DA5MR

Main runner cardboard box packaging system

DA5CT

Cross tee cardboard box packaging system

D59D D57, D58D

* taken as average output in linear metres of finished Cross Tee or Main Runner profiles

SYSTEMS FOR ROLLER SHUTTERS aluminium roller shutters and Venetian blinds Watch the videos!

Roller shutter profile is one of the product representing Dallan highest quality as the result of years of specialization in processing light-gauge, delicate materials such as aluminium and pre-painted sheet metal. Throughout its lifetime this type of profile, unlike others, is subject to daily stress caused by opening and closing of the shutter or blind. That is why in the design stage Dallan adheres to stringent design parameters formulated over the years and boasts a production of more than 300 roller shutter profiles to ensure optimum closing and winding, silent operation and blackout. This meticulous expertise has developed top quality products that are extremely sturdy, having even double the life expectancy of profiles with similar characteristics but made with other types of machine. Dallan has built up a wealth of experience in the field and created hundreds of profiles, researching the best use of the material to come up with top level state-of-the-art technical solutions and innovative roller shutter profiles to satisfy every type of requirement. For this reason, as in many other applications, several patents and solutions have been developed such as the DallanÂŽ | Light, featuring a new and attractive design, improved light control and ventilation, while letting in more light.

DALLAN D6: COMPLETE SYSTEMS, FROM THE COIL TO THE FINISHED PRODUCT READY FOR INSTALLATION

Dallan T4 roll former represents the core of D6 production systems, ideal for machining the lightest gauge and most delicate materials. Dallan has developed a complete range of lines and machines for the production of roller shutter bars, slats and curtains, from the simplest systems up to lines complete with the exclusive DALLANÂŽ COIL TO WINDOW technology for the automatic production of the finished shutter/blind packaged ready for installation. Production systems for making the accessories and complementary items such as the octagonal tube and shutter box profiles can be found in the D6 range.

Available versions Roll former

Product

Max. production rate

Machinable thickness

Machinable materials

D63

H15 – H55

37 m/min

0.2-0.6 mm

Al and steel

D610

H15 – H55

60 m/min

0.2-0.6 mm

Al and steel

D618

H15 – H55

80 m/min

0.25-0.6 mm

Al and steel

D6M

H55 – H77

30 m/min

0.4-0.8 mm

Al and steel

D6100

H77 – H100

25 m/min

0.6-0.9 mm

Al and steel

D6TL

H15 – H55

37 m/min

0.2-0.6 mm

D18

Octagonal tubes 40, 60, 70mm

D73

Duplex

Shutter box in 2 or 4 pieces

COIL TO WINDOW technology

Compatibility

COMPLEMENTARY ITEMS

AUTOMATION SYSTEMS

D6SK

Profile packaging system

D6T

Shutter/blind curtain assembly system with plastic clips

D610 D63, D610

SYSTEMS FOR external VENETIAN BLINDS

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The technical and design features of Venetian blinds profiles are extremely precise, as they need rigidity, straightness and a perfect surface. Just like the profiles for roller shutters, the Venetian blind profiles are a perfect application for the Dallan roll formers specialized in processing light gauge and delicate materials. Dallan has made a hundred or so different profiles since 1993, from the simplest flat and “C” slats to the “Z” and “S” slats and the new special and Omega slats. The design and constructional quality of the profiles are essential for the best light control inside the building and to achieve a quality design for the most prestigious applications. The use of these widespread products is increasing since they allow optimum control of incoming light with consequent considerable energy saving.

Dallan offers a whole range of production systems for Venetian blind profiles, which can be configured according to the required output, plus patented automated systems for the in-line application of accessories and assembly using Dallan COIL TO WINDOW technology. Stand-alone packing devices are also available, which can be applied to existing production lines. Part of the secret behind these high performance production systems lies in the cooperative relationships that Dallan has established with the main manufacturers of the relative accessories such as pins, hooks and textiles, resulting in the development of integrated production systems to make excellent and perfectly functional finished products.

D48 RANGE: AUTOMATION PRODUCTIVITY AND QUALITY AT MAXIMUM LEVELS Available versions Roll former

Product

Max. production rate

Machinable thickness

Machinable width

Compatibility

D48

Flat slat, rolled-edge C and Z and S slat

Depending on set-up

0.3-0.5 mm

30-100 mm

DPTC, DSC, DZC

D48V

Flat slat, rolled-edge C and Z and S slat

300-500 m2/day

0.3-0.5 mm

30-100 mm

DPTC, DSC, DZC

AUTOMATION SYSTEMS

DV1

Destacker for bundles of ready cut profiles

D48 - D48V

DPTC

System for application of end pins

D48 - D48V

DSC

Patented system of insertion onto string tape for C slats

D48 - D48V

DZC

Patented system of insertion onto loop tape for S and Z slats

D48 - D48V

SPECIALS

DOOR FRAMES AND PANELS parametric production and just-in-time production. Door frames consist of highly technical profiles whose characteristics differ according to the type of application while taking into account the all-important design and appearance. Depending on the application, the frames may be made with a single profile, as in the case of fire doors, or with two frames fixed to each other (subframe and external frame) which are assembled in the final stage of installation. With this type of application in mind, Dallan has made the D60 system for the manufacture of finished door frames, cut to size, with the choice of 45Â° or 90Â° cuts even on delicate and coated materials. The parametric production of the profile is a continuous process, the integrated in-line numerically controlled punching machine allowing the change of the profile dimensions at any time.

Roller shutter doors are made from very strong steel or aluminium profiles and are mainly used in commercial applications such as industrial doors, shops, etc.. They must guarantee outstanding strength given the dynamic nature of the application as the door is opened and closed at least once a day. The market also demands that increasing importance be given to appearance and design: in response Dallan has developed different roller shutter door profiles over the years, from flat slats to more complex models with curved, perforated or double-wall slats. Dallan production systems incorporate COMBI technology so that any changeover in type of profile is quick and easy, paving the way for a really efficient and flexible production strategy.

ROLLER SHUTTER DOORS DALLAN D16: system for flat and curved roller shutter doors • Decoiler • Dallan Roll former T4 • Fixed cutter • Unloading table DALLAN PR200: coil perforation for roller shutter doors • Decoiler • Feeder • Servo-electric press • Perforation die • Recoiler

DALLAN D164 and DALLAN INTEGRATED systems are designed for the production of 2 roller shutter door profiles, of the end slat and of the guides.

METAL FURNITURE AND SHELVING

AGRICULTURE

FAÇADES

Flexibility and productivity with the DALLAN CNC punching machine Metal furniture are made of different types of profiles, such as uprights and rectangular panels which are assembled and joined together to form different types of structure. Dallan production systems offer top level performance and quality with the in-line integration of Dalcos punching systems to give unrivalled output rates and flexibility. Dallan offers different lines according to the product to be manufactured, such as roll forming lines for panels, for uprights and for DALLAN high-capacity horizontal bars.

Versatile and automated lines Dallan offers production solutions for agricultural and stock-farming applications, which often require medium-high thickness profiles in galvanised sheet metal. Flexible systems have been developed for the parametric production of profiles for poultry sector and versatile systems for a myriad of applications such as fence posts and vineyard poles.

Dallan’s experience with pre-painted materials has been put to good use in developing production systems and forming sequences to create façade profiles of outstanding quality. This type of product is in is often made in aluminium, steel or delicate materials with lateral and front-back bending or folding. Such profiles are often mounted on other supporting profiles and their appearance must be impeccable.

HVAC Maximum flexibility and productivity with CNC punching Dallan has acquired a great deal of know-how also in the ventilation and air conditioning sector, developing efficient and versatile production lines, which incorporate exclusive Dalcos numerically controlled punching machines, for the manufacture of frames and vanes for ventilation dampers and for fire-rated dampers. Thanks to exclusive Dallan technologies, the roll forming systems for frames for splitter attenuators offer great flexibility and a surprisingly compact layout, which includes all the necessary processes such as punching, roll forming and cutting, to produce the finished product.

LIGHTING Productivity and quality for profiles in pre-painted material Profiles for light fittings are made with light-gauge sheet metal and have both technical and aesthetic function. Also in this case the combination of Dallan technology and its specialisation in machining light-gauge and delicate materials have resulted in highly flexible production systems to make top quality products also for the latest LED applications. DALLAN D86: lines for reflectors • Decoiler • Dalcos multipress • Dallan T4 roll former • Unloading table Dallan also provides systems for the manufacture of panels for lighting fixtures and ceiling lights that can be perfectly integrated into suspended ceiling systems with T-bars and look highly attractive.

SPECIAL PROFILES Based on more than 40 years continually evolving know-how, Dallan designs and constructs production lines for special profiles; these lines incorporate exclusive DALLAN technologies in processes such as: punching, perforating, drawing, laser cutting, roll forming and bending/folding, welding, assembly and packing.