The Skill Gap
A lack of experienced operators leads to longer setup times, test-scrap, and reliance on manual trial-and-error.
Tailored Upgrades and Retrofits
Give Your Plate and Angle Rolls a Second Life
The Challenge
Evolving Production Demands vs. Existing Machinery
In the heavy fabrication industry, your plate rolls and angle rolls are major capital assets designed to last for decades. However, as your business grows, you may face new challenges that your original machinery configuration wasn't built to handle. Purchasing an entirely new machine is a major capital investment that may not always be necessary.
New Technical Demands
Your current production mix requires tighter bending diameters, complex multi-radius profiles, or handling larger, heavier workpieces.
Changing Safety Standards
Older machinery might lack modern safety barriers, light curtains, or laser scanners required to protect your team and ensure compliance with updated regional regulations.
Technological Obsolescence
Outdated control systems slow down operations and prevent seamless integration with modern factory networks (MES/Industry 4.0).
The Davi Solution
On-Site Evaluation and Custom Engineering
Our specialist will inspect your installed plate rolls or angle rolls, analyze your current workflow, and identify mechanical, hydraulic, or electronic bottlenecks. Following this physical audit, our in-house R&D and Service & After Sales (SAS) engineering departments design a customized retrofit package tailored to your exact production goals.
retrofit 1
Next-Generation Control Systems
Upgrade your existing console to the iRoll Performance or iRoll eXtreme touch screen system (up to 21.5 inches). This allows you to generate automatic bending programs, simulate parts in 3D to prevent collisions, and integrate offline programming.
retrofit 2
Advanced Material Handling Accessories
We can retrofit modular accessories to automate plate handling on your 3-roll or 4-roll machines:
- Overhead supports and side supports to prevent large-diameter shells from collapsing under their own weight.
- Infeed and outfeed conveyors to accelerate cycle times.
retrofit 3
Tooling and Setup Upgrades for Angle Rolls
For your MCP angle rolls, we can integrate our Hydraulic Rolls Setup to allow rapid, non-manual adjustment of your universal rolls—reducing tooling change times and removing operators from hazardous areas.
retrofit 4
Modern Safety Packages
Bring your workshop up to the highest European and international safety standards by retrofitting light curtains, laser scanners, physical safety barriers, or badge-login operator management.
TECHNICAL FAQ
Upgrades & Retrofits
As wind energy foundations scale up, fabricators often struggle with the extreme structural deflection and precise roundness tolerances required during the calibration of heavy monopiles. Davi addresses this challenge by retrofitting your currently installed MAV machine with advanced high-capacity packages, such as the patented Servo-Tronic system for perfect rolls parallelism and our specialized "apple-shape" calculator software to automate ASME-compliant re-rolling. This tailored upgrade ensures you achieve perfect dimensional tolerances, minimizes manual rework on plates up to 150 mm (5.9 inches) thick, and optimizes torque distribution across all three motorized rolls to prevent plate slippage. Backed by our status as the wind industry leader with over 300 wind energy installations operating worldwide, our dedicated specialist can design this custom engineering package to extend your machine’s capabilities and safeguard your manufacturing continuity.
Many high-mix job shops face a severe shortage of skilled rolling operators, which leads to high test-scrap rates, slow setup times, and inconsistent cycle times on standard cylindrical cans. Davi solves this operational bottleneck by retrofitting your existing 4-roll machine with our state-of-the-art iRoll eXtreme control system, which can be seamlessly paired with custom plate-handling accessories like overhead supports, side supports, and automated infeed conveyors. This upgrade transforms your manual machine into an automated cell capable of importing DXF files and executing self-adjusting rolling sequences, delivering a massive boost in productivity and reducing your reliance on operator skill. With over 10,000 Davi machines installed globally, our R&D and Service teams ensure a smooth transition with remote commissioning assistance to maximize your return on investment.
In structural steel fabrication, manually adjusting universal rolls to switch between different profiles—such as channels, H-beams up to 1,200 mm (47.2 inches), or angles—is highly time-consuming and introduces safety hazards for operators working close to heavy tooling. Davi addresses this challenge by retrofitting your MCP angle roll with our non-manual Hydraulic Rolls Setup and the patented HD iRoll Camera system. This retrofitted combination provides a digital curvature template that allows operators to safely monitor bending accuracy in real time from the console, eliminating the need to constantly load, unload, and manually measure the section. Our heavy-duty section-bending technology is engineered under certified ISO 9001 and ISO 45001 systems, guaranteeing maximum operational safety and a significant reduction in downtime.
Operating older machinery that lacks modern safety enclosures poses a significant compliance risk and exposes your workshop team to preventable hazards, which can threaten your operational continuity. Davi provides a complete, modern safety retrofit package featuring certified light curtains, physical safety barriers, laser scanners, and secure badge-login operator management systems tailored to your specific shop floor layout. These integrated devices protect your personnel by immediately halting machine movement if a hazard is detected, bringing your equipment in line with the strictest international safety standards without compromising production efficiency. Engineered by our ISO 45001-certified team in Italy, this upgrade ensures long-term safety compliance and peace of mind for your workforce.
Maximize Your Machine Lifecycle
Request a consulation for upgrades and retrofits, now.