Commercial HVAC & Refrigeration: Are Roll Formed Parts a Fit?

It’s no secret the commercial HVAC and refrigeration industries are on the rise. Forecasters predict the global HVAC and refrigeration market will swell from $561 billion to $764 billion by 2026.

The collective push from consumers and governments toward energy efficiency is a huge driving force behind this predicted growth. 

In the HVAC industry, new construction and developments are contributing to the pace. According to Research and Markets:

“The increasing focus on environmental sustainability and green energy is pushing up the requirement for HVAC systems and services. In addition to this, the increasing construction and infrastructural development activities in the country are fueling the market advancement.”

In commercial refrigeration, Research and Markets reports consumer habits are leading growth: 

“The major growth drivers for this market are rapid growth in the organized retail sector, increasing demand for packaged food and beverages, rise in international food trade, and varying food consumption patterns to boost the sales of commercial refrigeration equipment.”

As your industry grows, it’s important you source your commercial HVAC and refrigeration materials from a manufacturer committed to quality, efficiency, and insight. 

Between global market expansion and stressed supply chains, there’s bound to be a lot of competition for refrigeration, heating, and cooling parts. Getting ahead of your rivals and finding a roll forming partner will be good for your business. Let’s explore why:

Metal Roll Forming HVAC & Refrigeration Materials

You’re going to need a lot of long, slender, metal parts. Producing them is a roll former’s specialty.

So, what is roll forming, exactly? This process involves heavy machinery that gradually bends flat sheet metal into a long, uniform profile by passing the material through a series of roll dies. 

A highly repeatable process, roll forming allows engineers and designers to create customized HVAC and refrigeration components. Once the tooling is in place, roll forming produces components more consistently than other metal shaping processes, even over long runs. 

Whether the parts you need are decorative or structural, a roll forming manufacturer can make them. Roll forming is the most economical process for creating:

•      Angles
•      Channels (U, C, J, box, hat)
•      Parts with complex, cross-sectional shapes
•      Parts with intricate hole patterns
•      Parts with continuous lengths of 20+ ft.

Hole punching, bending, and cutting to length can easily fit into one uninterrupted process rather than separate steps, making roll forming cost-effective and productive. 

Commercial HVAC and Refrigeration Parts Perfect for Roll Forming

Exactly which heating and cooling parts and refrigeration components benefit from roll forming?

Commercial HVAC Parts

Several interior and exterior structural parts of HVAC systems are roll formed. Roll forming produces:

• Air conditioner cases
• Cooling tower louvers
• Dampers
• Ducts
• Electric heater housings
• Filter frame units 
• Structural components and handrails for industrial chiller units

Even the tubing that’s part of the refrigerant exchanger in an HVAC system is made of roll formed copper. 

Commercial Refrigeration Parts

Meanwhile, roll forming is a huge part of the commercial refrigeration industry.  Frames for meat, dairy, and produce refrigeration units are roll formed, as well as: 

• Insulated shelving structures 
• Kick plates
• Protective sills
• Stainless steel handrails
• Textured decorative paneling

Whether you’re using stainless steel parts for framing or pre-painted aluminum sheets for decoration, roll forming produces a clean and attractive finish. 

Roll Forming Advantages

Roll forming has many advantages over other metal shaping methods. Original equipment manufacturers (OEMs) often turn to custom roll forming corporations for their ability to both form high-strength metals and work with:

• In-line features
• Complex profiles with intricate bending
• Tight, repeatable tolerances
• Large material size

Less Is More

When working with a roll former, less is more, as in: 

• Less tool maintenance – Because they produce parts and features in a continuous motion, there’s less strain on tooling.
  
  
• Less human error – Almost everything is automated, requiring less labor and reducing chances for mistakes. 
  
  
• Less scrap – In roll forming, scrap is typically 1-3% of your overall cost. That’s especially significant when you’re working with expensive materials.

Quality Is Key

Perhaps the biggest advantage of roll forming commercial HVAC and refrigeration parts is its consistency. Roll formed parts are consistently uniform across runs.

Roll forming machines also easily and precisely form high-strength steels while accommodating for springback distortion.

It’s also great for aesthetic projects where tool marks from other types of forming aren’t acceptable. 

Learn more about the anatomy of a roll forming line and the complete roll forming process: 

Find a Reliable Roll Forming Partner 

Many of the perks of roll forming are more about the processes certain roll formers adhere to, and not just the parts they produce. Look for a reliable partner with these capabilities: 

• Inventory management

• Product inventory – A “trigger-response” system is a highly efficient way to control inventory.
• Raw material inventory – The right roll former won’t hoard materials inventory, keeping your costs as close to market as possible.

• Quarterly reviews
• Customer feedback
• Inventory levels
• Raw materials prices

• Quality systems

• On-time delivery
• Low defect rate

• Safety

• Clean and organized facility
• Regular safety training & inspections

• Respected workforce

• Paid by skill – A good roll former knows they’re only as strong as their skilled labor force. The more skills a worker has, the more they get paid – meaning they’re highly invested in the quality of their work.
• Cross-trained – Having multiple skilled machinists means work doesn’t stop because one person gets sick. The whole team works together to produce your parts.

When you partner with a roll former providing all these services, you know they’re working to optimize the entire sourcing process.

Learn More: Commercial HVAC and Refrigeration Roll Forming Services & Capabilities

Need to know more about the roll forming process and how it can benefit the commercial HVAC and refrigeration industries? Download our free guide, “Why Roll Forming?”