When you are looking for a wide range of applications combined with high-precision tolerances across different materials—including extreme cone geometries and high-specification cans—and, above all, when no calibration is allowed after bending, the challenge quickly grows in complexity.
Part of the Engicon Group, Geldof brings extensive expertise across multiple sectors. Their capabilities range from the manufacturing of large-scale storage tanks for industries such as oil & gas, chemicals, and water treatment, to dry bulk storage solutions for agriculture, mining, and construction. In addition, they design and produce high-performance pressure vessels engineered to operate under extreme conditions, including high-pressure gases and corrosive environments.
In this context, a standard solution is not enough. What is required is a machine engineered around the customer’s process.
The challenge
The technical requirements were both ambitious and uncompromising:
- Guaranteed high-precision tolerances across a wide material range
- Plate thickness from 5 mm to 50 mm
- Full working width up to 3500 mm
- Material strength up to 690 N/mm² (MYS)
- Zero calibration allowed after bending
In addition, the solution had to ensure maximum flexibility, being capable of processing:
- Extreme cone geometries, typical in dry bulk projects
- Large site-built storage tanks
- High-specification cans for pressure vessels and silos
The solution
Faccin approached the project with a comprehensive engineering analysis, guided by a clear objective: to guarantee repeatability, precision, and operational reliability from the very first plate.
The solution for Geldof was the Faccin 4HEL plate rolling machine, equipped with Linear Guides Technology— a top-tier configuration designed to deliver unmatched accuracy in both prebending and rolling.
A flagship model, known for its productivity, automation, and consistent performance in medium and thick plate applications.
But there’s more behind it.
At Faccin, a machine is never just standard—it is engineered around the customer’s process.
In Geldof’s case, where no post-bending calibration is allowed, achieving target tolerances immediately was critical.
This requirement was met through a dedicated configuration, including an external preloading system for the top roll and the one under the bottom roll, ensuring consistent performance across the entire thickness range.
Accessories, settings, and technical solutions are never predefined. They are developed through close collaboration between the customer and Faccin’s engineering team—an approach that allowed the machine to be perfectly tailored to Geldof’s requirements.
A solid product portfolio sets the baseline—but every machine that leaves our factory is redefined by the specific process it is built to serve.
Advanced Handling System and Rolls motorization
Recognizing that handling would be a key factor in achieving the desired results, FACCIN engineered a highly customized solution including:
- Two extra-long multi-joint and walkable side supports with clamping system for the on-board tack welding
- A top support with wing-type technology for optimal plate control
- A 90° opening top beam, eliminating interference during extreme cone rolling
All axes are managed through the advanced SIEMENS CNC control, enhanced by a wireless remote system. Acting as a natural extension of the main console, the wireless interface gives operators full control of the rolling process from any position—improving flexibility, efficiency, and ease of operation.
To further enhance process control—especially with thin plates and conical plates—the machine was configured with all four rolls motorized, including the two side rolls with the exclusive features of using them in idle mode without the need of disassembling the motor-gearbox system
Smart Hydraulics & predictive maintenance
The system is designed to ensure maximum uptime and full operational continuity.
Thanks to a redundant hydraulic architecture, the machine continues working even in case a pump is under maintenance—eliminating the risk of costly downtime typical of traditional systems. All hydraulic functions are centralized and managed via fieldbus technology, replacing conventional wiring and enabling real-time monitoring, faster diagnostics, and remote service intervention.
Advanced algorithms continuously analyze machine parameters, enabling predictive maintenance and allowing issues to be identified before they impact production.
Conclusion
A state-of-the-art solution for a state-of-the-art engineering company—delivering precision, flexibility, and reliability at the highest level.
“From day one, FACCIN proved to be the partner we were looking for—capable of addressing our most demanding technical requirements. After two years of continuous operation, we can confidently say that no better choice could have been made.” — Dieter Vandeputte, Maintenance and Facility Manager, Geldof
Because the right companies recognize—and choose—each other.
Because trust is never taken lightly.
Thanks to
Geldof
Engicon nv (Geldof) is a leading provider of integrated steel solutions for storage, handling and processing of bulk solids, liquids and gases. Our services range from fabrication of individual equipment to realisation of complete EPC projects, supporting our clients throughout the entire lifecycle, from new build to repair and maintenance. Geldof offers storage tanks, dry bulk handling installations, pressure vessels and various other engineered constructions. Based in Belgium with references worldwide, we serve sectors spanning energy, bulk logistics, industrial processing and circular economy.
