Above: Millerbernd uses the MAV N30 to roll different grades of steel plate from 1½ in. to 4 in. thick and from 18 in. to 120 in. wide.

Plate roll technology combines short lead times with technical support to get manufacturer ramped up quickly

December 2017 - James Madison, father of the Constitution and fourth president of the United States, said, “There could be no success in governments, communities and families without trust.” If you ask Millerbernd Manufacturing Co., its owners would likely add “businesses” to Madison’s list. Trust is something the company has carefully cultivated with vendors, employees and customers for 84 years.

Paul Millerbernd opened a shop in Winsted, Minnesota, in 1933, welding everything from farm machinery to snowplows. The third-generation family business has more than 600,000 sq. ft. of manufacturing space sprawled across 55 acres, where 400 people produce standard and custom steel lighting poles and airport lighting bases and accessories. Millerbernd also rolls rings and cylinders for cement trucks, oil line seals, rail tanker cars, mining equipment and a host of other heavy-duty applications.

The MAV N30’s pull-power-design eliminates deflection and mechanical backlash of the frame to ensure maximum power in the rolling process.

Room to grow

When the shop sought to boost plate processing capacity, it turned to Davi Inc., for a new MAV N30 plate roll machine. “We wanted to strengthen a couple soft areas in our capabilities,” says President and CEO Trevor Millerbernd.

The plate and angle roll manufacturer is headquartered in Italy. Millerbernd found the Davi machine quality and performance attractive but it was the vendor’s ready inventory of equipment and after-the-sale support that tipped the balance.

“We were able to install the machine and ramp up production shortly after our decision to purchase the plate roll,” says Millerbernd. “The reduced lead time was an advantage for us. The faster we could get the machine in service, the faster we were able to produce revenue and better serve our customers.”

Typically, delivery for a high-capacity plate roll machine can take four to six months. “Our customers need short timeframes for installations,” says Davi General Manager Ettore Giambetti. “Our manufacturing philosophy is that we don’t wait. We carry a huge inventory of nearly 11,000 components at our logistics center in Italy. Our assembly plant is ready to build at any given moment.”

“We have gained extra plant capacity and higher productivity,” notes Millerbernd. “The MAV N30 was our first variable geometry plate roll so it was nice to have local Davi product experts and technicians to help us get up and running as soon as possible. They were able to assist us with troubleshooting during ramp-up.”

Giambetti claims Davi is the only one among its competitors that stocks dozens of machines in the U.S. with capacity up to 10 ft. by 4.75 in. “At the same time, we have machines in Italy ready for sale and immediate delivery in sizes up to 14 ft. by 8 in.” The mechanical components are built in Italy. These strategies work together to provide Davi customers “with reduced lead times of up to 70 percent.”

Millerbernd initially installed the semi-automated MAV N30 in 2014 to roll cylinders for wind turbine tower components. The machine operates 10 hours a day rolling various grades of steel plate from 1½ in. thick to 4 in. thick and from 18 in. to 120 in. wide.

Millerbernd rolls rings and cylinders for a wide range of heavy-duty applications that include custom work.

Variable geometry

The MAV N30’s variable geometry allows the operator to slide rolls in and out independently to leverage exertion of force to maximum advantage for any application. Unlike fixed-side, three-roll machines, the side roll can be positioned to minimize the flat end, allowing the MAV N30 to have the shortest flat end possible. The machine’s innovative “pull-power design” allows the cylinders to pull the top roll down and press it onto the plate. This eliminates physical deflection and mechanical backlash of the frame and ensures maximum power in the rolling process.

Conventional methods use one or both cylinders to push the top roll onto the plate adding stress and deflection to the machine frame for reduced accuracy and rigidity.

Three independent hydraulic motors and three gearboxes splined directly to each powered roll minimize the possibility of plate slipping. Automatic and hydraulic-assisted braking for all three powered rolls ensures accurate plate feeding.

“Davi’s technical and support teams listen to us and are very willing to work with us on our unique needs,” Millerbernd says. “We do a lot of special projects. They evaluate what we do and factored that into designing a custom machine that meets our needs.”

Information exchange

Davi invests in research and development but also invites customers to participate regularly in seminars to exchange and discuss information.

“We invest in technology based on what customers say they need on the production floor,” says Giambetti. “If we compare our machines to others on the market, the problem or challenge isn’t about making a better machine. It’s about whether you can support a customer by making sure your machine can effectively manufacture the customers’ products.”

As part of its support, Davi has established a strong dealership network. Nearly 90 percent of its machines are sold through dealers, giving customers the advantages of localized service.

“We keep in touch with Davi on a regular basis,” says Millerbernd. “It’s a tremendous value to us to have such a great partner in the rolling industry. The reliable performance of the MAV N30 and the assistance we know we can rely has us considering the purchase of another Davi machine.”

“We don’t just sell a machine,” Giambetti says. By developing trust, “we want to establish a partnership that will endure.” FFJ