FIELD OF THE INVENTION
The present invention relates to a system for achieving higher production and
productivity in Coil Corrugation Line for bulk production of Galvanized Corrugated sheet
in continuous coil corrugation plant. More particularly, the present invention relates to
increase the rate of production of Galvanized Corrugated Sheet by simply feeding
galvanized sheet coil from one additional 'Pay Off Reel' arranged in tandem with the
existing one at the entry zone such that two layers of input galvanized coils are pushed in
to the 24 stand forming mill at a time following the same pass line and then to a Cut-Off
press to finally cutting the processed Corrugated Sheets to the desired cutting length in
continuous operation. Thus the system of the present invention is directed to enhance
the production of Corrugated Galvanized Sheet in a simple and cost effective manner
with minimum alteration of the existing facility and capable of meeting the enhanced rate
of production at the time of sudden increase of demand of such products at the time of
natural calamities like flood, earth quake, tsunami etc. for rehabilitation of the victims or
like other situation. Advantageously, the system of the present invention provides a very „
cost effective solution to enhance/double the production rate in any single pass line with
existing single Pay-Off Reel Continuous Coil Corrugation plant for producing Galvanized
Corrugated sheets of a wide range of finished sizes maintaining desired quality.
BACKGROUND ART
It is known in the related processing line for production of galvanized corrugated sheets
in steel plants and similar other industries wherein bulk production of corrugated
Galvanized sheets are required, that a Continuous Coil Corrugation is produced in various
size ranges such as length of 1.5 meter to 6.0 meter, Width of 800mm and thickness of
0.45 to 1.5 mm. Usually, such plants are having only one pass line and one Pay-Off Reel
in corrugation line for feeding input coil. In this existing type of single pass line plants,
input materials Galvanized sheet/coil is fed in "Pay Off Reel" at entry zone and enters
into a 24 stand Forming Mill where Galvanized Sheet is turned into corrugated shape.
After Corrugated sheet is produced in a continuous plant, the processed materials next
enter into 'Cut-Off Press' machine for continuous cutting of corrugated sheet according to
a setting length. The existing plants having only one pass line and one Pay-Off Reel in

the corrugation line for feeding the input coil, it is very difficult to increase the rate of
production as and when needed. More importantly, when the demand soars up under
crisis situation such as caused due to natural calamities like flood, earthquake or like, the
existing set up of the galvanized corrugation sheet production line is not sufficient to
meet such enormous momentary rise in demand. No existing production facility could
provide any cost-effective solution to boost the production of corrugated GI sheet without
much of capital investment or introducing high end technology, but by making simple use
of existing infrastructure with minor additional facilities.
There has therefore been a persistent need in the existing art for developing means for
reliable and economic method to increase production and productivity in the continuous
coil corrugation sheet production plant in steel plants or the like. The present invention is
thus an attempt to solve the existing problem of substantially increasing the rate of
production of the corrugated sheet from the existing level, to meet sudden rise in
demand in the same plant with very nominal addition of equipments and facilities.
OBJECTS OF THE INVENTION
The basic object of the present invention is directed to developing a reliable and
economic system for production and enhancing productivity of the galvanized corrugated
sheets to meet increased demand, utilizing the basic infrastructure facility with addition
of minimum additional equipments, avoiding much investment on capital asset addition
or increase in related fixed costs.
A further aspect of the present invention is directed to developing a system for increasing
production of galvanized corrugated sheets by using another additional uncoiler with Pay-
Off-Reel in the same pass line before the forming mill for processing/forming two layers
of sheets for corrugation and then sent to cut off press for cutting to desired length to
thereby obtain two pieces of corrugated sheets in a single pass.
A still further object of the present invention is directed to developing a system for
increased production and productivity in production line for corrugated galvanized sheets

by addition of one Pay-off Reel with uncoiler before the forming mill in the same pass line
and a method for its implementation so as to achieve lower cost of operation and
maintenance.
A still further object of the present invention is directed to developing a system for
increased production and productivity for production of corrugated galvanized sheets is
directed to achieving improved capacity utilization of the existing Galvanized sheet
corrugation line with less/existing manpower.
A still further object of the present invention is directed to developing a system for
increased production and productivity for production of corrugated galvanized sheets
wherein the system is adapted to produce any range of size of corrugated galvanized
sheet from the same production set-up at higher rates according to market demand.
A still further object of the present invention is directed to developing a system for
increased production and productivity for production of corrugated galvanized sheets with
superior quality at less cost due to improved productivity.
SUMMARY OF THE INVENTION
The basic aspect of the present invention is thus directed to a system for bulk production
of galvanized corrugated sheets in continuous coil corrugation plant for increased
production/productivity, comprising
a first uncoiler unit at the entry zone for feeding input coil of one layer of galvanized
sheet in one pass line to a forming mill;
an additional coil feeding arrangement in the same pass line comprising a second
uncoiler unit adapted for feeding a second layer of galvanized sheet over the said first
layer selectively disposed therebetween the first uncoiler unit and the said forming mill;
said forming mill adapted to receive simultaneously said two layers of galvanized sheets
to generate desired corrugated shape on the sheets at a time ;

a Cut Off press for continuous cutting of the two layers of galvanized corrugated sheets
in a setting length, to thereby favor enhanced rate of production.
A further aspect of the present invention is directed to a system for bulk production of
galvanized corrugated sheets wherein said second uncoiler unit comprise a pay off reel
on a support structure.
A still further aspect of the present invention is directed to a system for bulk production
of galvanized corrugated sheet, wherein said second additional uncoiler unit with
galvanized sheet coil is installed with suitable support structure just before the Forming
Mill for feeding of the second layer of galvanized sheet over the first layer simultaneously
in one pass line of the corrugation plant for pushing through the Forming mill and cut off
press.
According to yet another aspect of the present invention directed to said system for bulk
production of galvanized corrugated sheet in continuous coil corrugation plant, wherein
said forming mill is preferably a 24 stand forming mill where sheets are turned into
corrugated shape.
A still further aspect of the present invention is directed to a system for bulk production
of galvanized corrugated sheet in continuous coil corrugation plant, adapted to produce
finished dimensions of the galvanized corrugated sheet comprising a wide range
preferably the length of 1.5 meter to 6.0 meter, width of 80(Tmm, thickness of 0.45mm
to 1.5 mm.
According to a further aspect of the present invention is directed to a method for
increasing rate of production of galvanized corrugated sheet in the continuous coil
corrugation plant according to said system of the following the steps of
providing a first layer of input feeding of galvanized sheet from said first uncoiler with
pay off reel at the entry zone to the one pass line of continuous corrugation plant;
providing a second layer of input feeding galvanized sheet over said first layer from said
additional uncoiler feeding arrangement prepared and fixed just before the forming mill;

said two layers of galvanized sheet one over the other simultaneously are pushed
through the forming mill for simultaneously transforming the two layers of sheets into
corrugated shape;
the processed galvanized corrugated sheets in two layers subjected simultaneously to
said 'Cut-Off Press' for continuous cutting of corrugated sheet in a setting length; to
thereby achieve desired higher rate of production of corrugated sheets of desired
dimensions.
The present invention and its objects and advantages are described in greater details
with reference to the accompanying non limiting illustrative drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
Figure 1: is the schematic illustration of the conventional coil corrugation line showing
the single pass with single Pay-Off coil at entry zone only.
Figure 2: is the schematic illustration of the production line according to the present
invention providing an additional Pay-off coil with uncoiler unit for feeding two galvanized
sheet at a time in to the forming mill to increase the production and productivity of the
plant.
Figure 3: is the illustration of the front view and sectional end/side view of the additional
uncoiler unit along with the support structure for its installation just before the Forming
Mill for desired increased rate of production of corrugated galvanized sheet according to
the present invention.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE
ACCOMPANYING FIGURES
Reference is first invited to the accompanying Figure 1 that schematically illustrates the
existing galvanized sheet corrugation line using one pass line and one Pay-Off Reel at the
entry zone. It is clearly evident from the accompanying Figure 1 that the galvanized

sheet of desired thickness is fed through the pass line from a pay-off reel at the entry
zone by an uncoiier and a set of traversing roll bed wherein there is also provision for pit
with cobble sheer to take care of cobble/loop formed due to any variation in tension in
the galvanized sheet during the processing through the single pass line. The sheet is
pushed through the 24 stand Forming Mill that turn the sheet in to the corrugated shape
on the galvanized sheet. The galvanized corrugated sheet is next fed to a Cut Off press
machine in the processing line to cut the processed material based on a setting length. It
is known in the existing art that the conventional Continuous Coil Corrugation plant for
production of Galvanized corrugated sheet is adapted for a wide range of overall
dimensions comprising Length of 1.5m to 6.0 m, Width of 800 mm, thickness of 0.45 mm
to 1.5 mm.
Reference is now invited to the accompanying Figure 2, that schematically illustrates the
modified corrugation line utilizing the existing single pass line for desired increased
production rate of coil corrugation introducing one additional pay-off reel in the line
before the "Forming mill such that the system is adapted for feeding two galvanized
coils/sheets at a time in coil corrugation line to increase the rate of production of
galvanized corrugated sheet. It is clearly apparent from the accompanying Figure 2, that
an additional coil feeding arrangement prepared and fixed with necessary supporting
structure just before Forming Mill. This additional for coil feeding arrangement provide
means for pushing two layers of input Galvanized Sheet material in Forming Mill such
that two layers of sheets are formed simultaneously to produce corrugated sheet of
desired dimension/width/thickness.
Reference is now invited to the accompanying Figure 3, that shows the front view and
the sectional side view of the additional uncoiier with pay off reel providing feeding of a
additional layer of galvanized sheet according to the present invention. It is apparent
from Figure 3 that the height of support structure of the uncoiier is so maintained with
respect to the existing single pass line for the galvanized corrugation plant, that the
additional feed layer of galvanized sheet from the additional pay off reel is fed through
the Forming Mill as a layer over the existing sheet material fed from the uncoiier at the
entry zone. The shaft of the uncoiier is having detachable bearing support so that once a
coil is consumed, a new galvanized coil can be freshly loaded. Once the corrugated
sheets are formed two at a time to desired length, they are then fed through the 'Cut of
Press' for continuous cutting according to a setting length. Thus the present system with

one additional uncoiler in the same single pass line of the coil corrugation line is adapted
to increase the rate of production and productivity by about double in a reliable and cost
effective manner with minimum addition of infrastructure facility and therefore low fixed
costs. The system of the present invention is capable of forming corrugation of two layers
of galvanized sheet at a time and thus saves on equipments and manpower while
increasing the production and productivity of coil corrugation plant in order to meet any
hike in market demand at reasonable cost without compromising on quality of finished
product.
It is thus possible by way of the present invention to developing a system for enhancing
the rate of production and the productivity of the galvanized sheet in a simple and cost
effective manner by just addition of one uncoiler with pay off reel for input of one
additional galvanized sheet simultaneously in the single pass line such as to feed two
layers of sheets in the forming mill to produce corrugated sheets two at a time in two
layers and cut to desired length at Cut Off Press as per setting length. The system and
method of the invention for increased production of the corrugated galvanized sheet
having low operational and maintenance costs and improved utilization of the installed
capacity and available manpower, thus favoring wide application of such systems in
corrugated galvanized sheet manufacturing units in steel plants or similar other
intermediary industries.

We Claim:
1. A system for bulk production of galvanized corrugated sheets in continuous coil
corrugation plant for Increased production/productivity, comprising
a first uncoiler unit at the entry zone for feeding input coil of one layer of galvanized
sheet in one pass line to a forming mill;
an additional coil feeding arrangement in the same pass line comprising a second
uncoiler unit adapted for feeding a second layer of galvanized sheet over the said first
layer selectively disposed therebetween the first uncoiler unit and the said forming mill;
said forming mill adapted to receive simultaneously said two layers of galvanized sheets
to generate desired corrugated shape on the sheets at a time ;
a cut off press for continuous cutting of the two layers of galvanized corrugated sheets in
a setting length, to thereby favor enhanced rate of production.
2. A system for bulk production of galvanized corrugated sheets as claimed in claim 1
wherein said second uncoiler unit comprise a pay off reel on a support structure.
3. A system for bulk production of galvanized corrugated sheet as claimed in anyone of
claims 1 or 2, wherein said second additional uncoiler unit with galvanized sheet coil is
installed with suitable support structure just before the Forming Mill for feeding of the
second layer of galvanized sheet over the first layer simultaneously in one pass line of
the corrugation plant for pushing through the Forming mill and cut off press.
4. A system for bulk production of galvanized corrugated sheet in continuous coil
corrugation plant as claimed in any one of claims 1 to 3, wherein said forming mill is
preferably a 24 stand forming mill where sheets are turned into corrugated shape.

5. A system for bulk production of galvanized corrugated sheet in continuous coil
corrugation plant as claimed in anyone of claims 1 to 4, adapted to produce finished
dimensions of the galvanized corrugated sheet comprising a wide range preferably the
length of 1.5 meter to 6.0 meter, width of 800 mm, thickness of 0.45mm to 1.5 mm.
6. A method for increasing rate of production of galvanized corrugated sheet in the
continuous coil corrugation plant according to the system as claimed in claims 1 to 5
following the steps of
providing a first layer of input feeding of galvanized sheet from said first uncoiler with
pay off reel at the entry zone to the one pass line of continuous corrugation plant;
providing a second layer of input feeding galvanized sheet over said first layer from said
additional uncoiler feeding arrangement prepared and fixed just before the forming mill;
said two layers of galvanized sheet one over the other simultaneously are pushed
through the forming mill for simultaneously transforming the two layers of sheets into
corrugated shape;
the processed galvanized corrugated sheets in two layers subjected simultaneously to
said 'Cut-Off Press' for continuous cutting of corrugated sheet in a setting length; to
thereby achieve desired higher rate of production of corrugated sheets of desired
dimensions.
7. A system for bulk production of galvanized corrugated sheet in continuous coil
corrugation plant and a method for increasing rate of production of such sheets as
hereindescribed with reference to the accompanying non-limiting illustrative figures.

The present invention relates to a system to increase production and productivity in
continuous coil corrugation plant producing Galvanized Corrugated sheets. More
particularly, the system increases the rate of production of Galvanized Corrugated Sheet
by simply feeding galvanized sheet coil from one additional 'Pay Off Reel' arranged in tandem with the existing one at the entry zone such that two layers of input galvanized coils are pushed in to the 24 stand forming mill at a time following the same pass line and then to a Cut-Off press to finally cutting the processed Corrugated Sheets to the desired cutting length in continuous operation. Thus the system of the present invention is directed to enhance the production of Corrugated Galvanized Sheet in a simple and cost effective manner with minimum alteration of the existing facility and capable of meeting the enhanced rate of production maintaining desired quality, at the time of
sudden increase of demand, favoring wide industrial applications.