Metals, Steel, Aluminum & Coil Processing worked example

Roll Forming Speed at 99% line efficiency: a worked example

This scenario runs the roll forming speed calculation on the strong side: 99% line efficiency, with every other input held at its documented default. Use it when retuning a roll former for a new profile and you want a line speed that matches the required output on the first try.

The inputs for this scenario

  • Required finished pieces per hour: 400 pieces / hr (unchanged)
  • Cut length per piece: 18 in (unchanged)
  • Line efficiency: 99 % (raised for this scenario; the documented default is 90)

Working through the calculation

  • Applying the documented formula (Required piece rate = required piece output รท line efficiency) to the inputs above produces each figure below.
  • At this operating point the engine returns 10.1 ft/min for required line speed, the number this scenario is built around.
  • At this operating point the engine returns 404 pieces / hr for required piece rate.
  • At this operating point the engine returns 18 in for cut length per piece.
  • At this operating point the engine returns 99 % for line efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where line efficiency sits at 90% and the headline result is 11.11 ft/min, this scenario comes in 9.09% below the baseline at 10.1 ft/min.
  • Use it during job setup or capacity checks to verify the line can hit target output and to set the initial drive speed for a profile. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Required line speed: 10.1 ft/min (headline result)
  • Required piece rate: 404 pieces / hr
  • Cut length per piece: 18 in
  • Line efficiency: 99 %

Run it with your numbers

  • Every input above is editable in the live Roll Forming Speed calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.