As the industry-leading designer and manufacturer of the most complete and advanced sheet metal forming solutions, Mestek Machinery makes it a priority to continue a legacy of innovation centered on making duct fabrication easier for the contractor and propelling the HVAC duct fabrication industry forward. One of the most impactful innovations that Mestek Machinery has brought to the market in recent years is the integration of the capability to produce finished duct with a full-engagement longitudinal seam into the Iowa Precision Pro-Fabriduct Full Coil Line.
In order to remain at the forefront of the precision technologies, software, and automation that is quickly dominating the sheet metal fabrication field, Mestek Machinery and its representatives make a point of staying up to date on industry trends not only at home but also abroad.
Within the past four years, Mestek Machinery has honed in on more advanced European sheet metal forming technologies and equipment, especially in the production of finished duct. Namely, Mestek Machinery experts perceived the value of the European method for producing full-width longitudinal seams, and in 2020, began work on a plan to integrate that forming technology directly into the duct line.
The result? Rigorous testing in conjunction with SMACNA has shown that the Full Width Longitudinal Seam Ducts produced with the Iowa Precision Pro-Fabriduct Full Coil Line demonstrate a 25% reduction in the chance of leakage across different gauges and different size ducts, providing a substantial impact on product quality while lowering post-production labor costs.
In this video from SMACNA, Mike Bailey, Mestek Machinery's Senior Vice President of Sales, shares how the Pro-Fabriduct was reengineered to reduce leakage as well as what "innovation" means to Mestek Machinery and its family of brands.
Most HVAC duct leakage occurs at the notch hole that is produced at the top and bottom of a duct section at the transverse duct connection to the fan or the unit. The Iowa Precision Pro-Fabriduct Full Coil Line has undergone a combination of modifications to the processor, transfer system, and hydraulic servo wrap brake. These modifications give the Pro-Fabriduct the ability to produce a full-engagement longitudinal seam, allowing sheet metal fabricators to deliver a finished duct with substantially reduced chances of leakage in the corners of the duct’s transverse joint across gauges and duct sizes.
The notch profile is altered to leave more material on the male side of the notch, allowing the male seam to extend to the edge of the duct. Dual stepper-motor controlled notching die positioning eliminates an operator from needing to adjust the notchers for coil width or notch type; precise positioning is handled through the control system. The 90˚ male lock is formed after the roll forming of the connecting flange, avoiding the full length male flange from being deformed as it passes through the roll former. The servo wrap brake is altered to include locating pins to accurately locate the part parallel to the bending beam. Positioning of the leading raw edge gives very accurate and precise locations for the subsequent bends. Computer controlled leaf tooling gags have been added allowing the brake to bend the full engagement male lock seam without deformation.
Mestek Machinery has made significant strides in terms of technology and process innovation for decades, leading the industry with the most reliable equipment that is continually designed and redesigned to produce better duct and streamline shop flow. With a commitment to innovation and improvement, Mestek Machinery continues as the industry-leading designer and manufacturer of the most complete, productive, and state-of-the-art metal forming solutions for the fabrication of HVAC sheet metal duct product that reflect a well-earned reputation for quality. Backed by over 100 years of expertise and experience in metal forming and fabrication, the company has grown and continues to grow alongside the network of sheet metal contractors and manufacturers.