Bradbury Group  

1200 E Cole
Moundridge,  KS  67107-0667

United States
620-345-6394
http://www.bradburygroup.com

Helping you get what you want, need, and expect from an equipment manufacturer is the goal of every employee in The Bradbury Group. To accomplish this, we take a very proactive team approach to engineering and manufacturing quality equipment and supporting your investment with exemplary service. This is the culture we are committed to. 

The Bradbury Group of companies make an extensive line of coil processing, roll forming, and related equipment and controls for a broad range of industries including Metal Building, Trim Shops, Metal Tile Roofing, Grain Bins and Grain Storage, Coil Processing, Cut-To-Length, Leveling, Decking, Steel Framing, Garage Doors, HVAC, Railroad, Custom Rollforming, Heavy Gauge Rollforming, Transportation & Highway, Automotive, Automated Production Systems, Lighting, Shelving & Racking, and Appliance. 


 Press Releases

  • The FlatTrak® CL Strip Evaluation System is Bradbury's recent technological evolution that utilizes artificial intelligence to analyze strip condition and provide suggested adjustments to your leveler to process flat material. FLat Trak CL_blog 2

    How does it work? Bradbury’s FlatTrak® CL continuously scans the strip surface for shape defects. The included video monitor depicts actual shape conditions in real time and allows the operator to make an informed decision for adjustment to improve flatness. The operator can adjust the leveler and see in real time how the changes affect material shape. When installed with the Bradbury e•Drive® Leveler, the Flat Trak® CL System can automatically adjust the leveler to maintain a flat strip, allowing your operator to focus on other production line tasks.   

    Bradbury FlatTrak Graphic DisplayWhat if you don't own a Bradbury leveler? The Flat Trak® CL may be placed in your line even if you don't have a Bradbury leveler. It will monitor the strip and provide a recommended roll shape to manually correct the strip shape defect. The operator can adjust the leveler and see in real time how the changes affect material shape. 

    What is included with the FlatTrak® CL system?  It comes with a material conveyor equipped with a flat measuring surface to match your pass line and line width. A dedicated material encoder is used to identify strip travel length.  An “end of coil” proximity switch is installed to signal the coil is complete and ready to reset. The dedicated PLC, I/O, and amplifiers are enclosed in the machine junction box.   

    Remove the stress in your production line. 

    •Let the Flat Trak® CL do the work for you.

    •Allow your operator to focus on other tasks.

    •Produce a flat, stress free strip.

    •Improve your end product. 

    To learn more about our company and the equipment we have to offer visit bradburygroup.com

  • Our roll tooling training course includes classroom instruction and hands on training! 

    You've invested in Bradbury roll forming equipment for maximum production at your facility, so why not invest in your employees with roll tooling training from an industry expert? At Bradbury, we believe in investing in our people and our processes. This commitment extends to our customers. Bradbury Roll Tooling Training Course

    Ron Dies, Bradbury Technical Training Director & Preventative Maintenance, will instruct and guide your employees during a full day of technical roll tooling training. With nearly 20 years of direct experience with Bradbury equipment, Ron has a vast amount of knowledge to share with you regarding equipment install, maintenance, line operation, and more. 

    The one-day course includes five to six hours of classroom instruction and two to three hours of engaged, hands-on training. Although having the course at Bradbury is an option, we recommend having the training at your facility. This allows Ron the opportunity to work with your employees on the machine they operate and resolve any questions or concerns they may currently have.

    The class will cover four main topics: 

    1. Learn to read and understand Bradbury's roll tooling prints and discover how Bradbury designs roll tooling.Ron_Equipment_Bradbury_Training
    2. Learn to assemble Bradbury mills to prepare for roll tooling and how to install Bradbury raft plates. 
    3. Learn to properly set up, calibrate, and align Bradbury roll tooling. 
    4. Learn to accurately diagnose and troubleshoot profile issues. 

    We encourage you to include seasoned operators, new operators, maintenance technicians, quality control inspectors, safety coordinators, etc. in this training. Everyone will benefit from this experience. 

    The Bradbury Group takes a very proactive approach to engineering and manufacturing quality equipment and supporting your investment with exemplary service. We want to help your equipment maintain top performance production. 

    Contact us to discuss class size options, cost, and the advantages this course will bring to your production.

    Call +1.620.345.6394

    or submit the form below and we will contact you. 

  • Bradbury AG Roll Tooling is Designed to Form the Best Panels in the Industry

    By Ben Schmidt, Bradbury Industry Sales Manager

    Did you know Bradbury AG roll tooling offers several advantages our competitors do not? From forming a superior panel toBradbury Ag Panel production longevity, Bradbury AG roll tooling leads the industry. If you want to manufacture consistent, top-quality panels, our tooling is designed to prevent common AG panel deformations and have a longer production life.

    Let’s take a brief look at common AG panel deformities, what causes them, and why Bradbury roll tooling can help prevent these issues. Typically, to diagnose a tooling issue, one should assess the AG panel that is being produced. Panel coverage running wide, reduced panel features, wavy overlap edge, crossbow (panel flatness), large bending radii, and degraded cut quality on post-cut lines are signs there is likely a problem with the roll tooling. It could be caused by normal wear and tear with the tooling, or it might be a low-quality roll former and tooling. 

    Creating a panel with tight bends is the key to a stronger panel – which is crucial to the roofing customer. If the panel is running wide, most likely the major and minor ribs have a reduction in sharpness. The tooling is causing the metal to spread out instead of creating sharp edges. On the major ribs, the form will start to round. On minor ribs, it may turn into a half-moon instead of a crisp rib. The panel is wider because a round bend does not take as much steel.

    As the bending radii of the tooling start to wear and loosen over time, it takes more pressure to create a ¾” rib. As the tooling comes down tighter it causes the panel to lose angles; once the ability to adjust the panel is lost, the ability to control flatness is lost.

    In the roofing business, a weather-tight lap is essential. If a panel has a wavy edge it will not have a tight lap. It’s challenging for installers to get a tight lap if the ribs are not consistent in the panels being installed and overlapped.

    You may be able to find a solution to these common issues with a few adjustments to your machine. By calibrating your Bradbury Roll Tooling Training Coursemachine, you will set your vertical clearances, your horizontal clearances, and your pass to pass settings to confirm alignment.  Bradbury offers a roll tooling training course which includes classroom instruction and hands-on training led by Ron Dies, Bradbury Technical Training Director & Preventative Maintenance. 

    If you still have sub-par quality panels after the calibration process, you have three options: retrace or recut the roll tooling, partial tooling replacement, or a complete tooling replacement. However, putting new tooling on a worn-out machine will not solve your problem. For optimal improvement, you will need to replace the roll former stand bearings and the adjustment assemblies. We also recommend inspecting sprockets, chains, spur gears, drive rolls, and arbors.

    Quality equipment is well worth the investment. Here are a few advantages of investing in Bradbury AG roll tooling:

    All Bradbury AG panel tool sets come with a bow correction fixture. The bow correction fixture removes the banana or canoe appearance of major ribs.  Bow occurs because a small bend is formed in a small area.  Excessive bow can result in an open lap and a panel that does not lay flat.

    Bradbury AG panel tool sets have 212 main forming rolls and 10 straightener rolls.  On average, this is 40% more pieces of tooling than other suppliers.  More pieces of tooling allow critical overform bends to be separated.  Separating overform bends provides an operator with the opportunity to adjust for different types of steel.

    Bradbury Panel LineBradbury AG panel tool sets require a minimum of 3.5” diameter arbors.  Larger arbor diameter reduces the amount of deflection.  Reducing deflection provides uniform forming of high wear features.  Specific AG panel high wear features are the minor ribs.  Bradbury AG panel tool set produces an identical middle cell of minor ribs to the outer minor ribs.  Other suppliers use a 3” (or smaller) diameter arbor which has a higher likelihood of arbor deflection.  Arbor deflection is exposed in high wear areas on AG panels.  Tool sets with arbor deflection do not produce a uniform minor rib.  The middle cells are significantly less defined than the other cells.

    Bradbury AG panel tool sets are designed with 7” pitch forming.  The larger equal geared pitch forming requires larger outside diameter rolls.  The larger rolls result in more footage per revolution which creates better longevity for a tool set.

    Bradbury AG panel tool sets are made with through-hardened tool steel.  Through hardened tool steel allows tool sets to be recut and still provide the same level of wear resistance.  Other suppliers achieve wear resistance by applying a thick level of chrome to unhardened tools.  When the chrome wears off, the unhardened tools will be damaged to the point of not being able to recut, which results in purchasing new tools.  Thick layers of chrome can create buildup which can change the engineered tooling clearances.

    Since 1959, Bradbury has been a respected leader in the metal building industry. The products being formed on our machines are top quality and bring a competitive edge to our customers. Call to discuss how Bradbury equipment can increase your production and profit. 

    Call +1.620.345.6394

  • The Bradbury Coil Joining Unit Keeps Your IMP Production Running

    A continuous sandwich panel line needs to run production non-stop even during a coil change. If a continuous line stops duringCoil Joiner.321 production, it can result in several meters of scrap panel and wasted time. By utilizing a Bradbury automated coil joining unit and four uncoilers, a Bradbury continuous insulated metal panel line automatically joins coils together for uninterrupted manufacturing of panels.

    How does the coil joining process work?  As the coil in process is depleted, the new coil is fed directly to the trail end of the leading coil.

    Positioned by coated rolls, the material is fed through a shearing station which generates straight ends on both strips. The strips continue through the joining unit, end to end, where they are connected by the automated adhesive process. The strip accumulating station allows the line to continue while the joining station is activated.

    What advantage does this system bring to your production? The automated joining unit allows you to safely change the color of your panel on the fly or simply add another coil without stopping the line. Our smart controls know where to cut your panel to remove the adhesive seam with a minimal amount of scrap. The joining unit is a stand-alone system and can be installed into any production line.

    Double-BeltBradbury Group manufactures continuous and discontinuous insulated metal panel production lines using EPS, Mineral Wool, PIR/PUR, and flexible backing. Our continuous lines offer entry coil handling to exit-end packaging, utilizing preconditioning of the incoming material with precision leveling and rotary embossing.  Whether for the garage door market, commercial buildings, cold storage, or the HVAC industry, Bradbury can meet your requirements.

    Bradbury also offers discontinuous panel production lines for polyurethane-filled panels including insulated wall and roof building panels, garage doors, entry doors, and refrigeration coolers. Discontinuous plants allow for fast and flexible color and profile changeovers of insulated panels.

    With insulated metal panel equipment installed around the world, The Bradbury Group is a single source supplier of the most technologically advanced insulated metal panel production lines available. Call us to learn more or email bradbury@bradburygroup.com.

    We look forward to talking to you about this line and any other equipment needs you may have.

    Call +1.620.345.6394

  • Most Cut to Length lines suffer from a bottleneck in production at the exit end of the line due to customers' unique line_stacksrequirements for packaging the CTL sheets or plates. These customer-driven stipulations can be quite extensive and labor-intensive for the line operators. End customers today are requesting smaller stacks and more frequent deliveries to manage their cash flow more effectively. This puts additional pressure on the line operator due to the increased number of packaged stacks the line must produce. 

    Requirements from the end customer might include the following:

    • Strapping sheets both horizontal and vertical directions.
    • Strapping dunnage to the sheets both horizontal and vertical directions.
    • Protective wrapping such as paper or plastic.
    • Stacks with or without wooden skids.
    • Corner protectors
    • Shrink wrap

    Athader S.L., a company within The Bradbury Group, offers the following automated stacking and packaging solutions to improve throughput efficiency:  

    • Storage of packs via roller and chain type conveyors.ATHADER
    • Ability to discharge scrap pieces without manual lifting.
    • Automated insertion of corner protectors. 
    • Pack Lifter – This is used to elevate a stack of sheets that have exited the stacker. Once elevated the package can be easily wrapped.
    • Wrapping Systems - Height wrapping can be manual or automated; Width wrapping can be automated via an orbital wrapper.
    • Automatic dunnage retrieval from an organized pack by robot or by a dunnage cartridge system.
    • Automatic dunnage insertion under the stack of sheets.
    • Automatic strapping of the dunnage to the stack of sheets.
    • Automatic formation of a master stack of sheets via an automated sheet lifter and/or gantry crane.
    • Once the master stack of sheets is built, the sheets are deposited onto the floor for removal by the main overhead crane and put into the storage area.
    • Cloud-based data storage/tracking system including package specific details, machine status, faults or stoppages, and production levels. Over time this system can provide information on areas of needed improvement to further increase production or help the owner identify the packaging costs to improve the management of as sold costs. 

    Athader packaging lineThe automated packaging of sheets or plates can be custom engineered to suit the line operation requirements. Using these automated features, lines have increased output up to 30%, allowing the owner to reduce manpower and increase productivity. 

    Athader S.L. designs and manufactures Slitting, CTL, and Packaging lines for both Slit Coils and CTL Sheets/Plates. Learn more about our products at www.athader.com.

    Call +1.620.345.6394

  • Calendering:  A process that plays a part in all our lives, yet most of us have no idea what it is. From disposable diapers to dryer sheets, to disinfectant wipes, to rubber tires, to PVC films used on laminate floors, to healthcare protective equipment, and many more - calendering  is vital to the production of thousands of products used every day.  

    Calendering is the process of pressing a continuous web or substrate, such as cloth, rubber, paper, film, nonwoven,Alliance calender entry composite, wire mesh, etc., between rollers to create specific physical characteristics. These can include controlled thickness, surface finish, and required properties such as structural reliability, liquid absorption, and abrasion resistance.

    Alliance Machine and EngravingAlliance Machine and Engraving, LLC manufactures custom calender machines for numerous industries. The calenders employ two or more steel rolls that close under pressure to smooth, compress, and in some cases partially bond a nonwoven, plastic, paper, or another substrate. The rollers may be mirror-smooth, embossed with a pattern, or porous, and are usually heated with hot oil or electric elements. The calender machines can be utilized in an independent converting setting or an integrated production facility. Each designed with a specific application, Alliance calenders currently in use range from 260” wide to less than 12” wide.   

    When processing certain webs such as fine paper or precision magnetic tapes, a calender will have a stack of rolls through which the web is threaded. This is referred to as a supercalender. 

    Alliance calender exitMany nonwoven’s need to be calendered as part of their production or finishing process. The combination of heat and pressure seals and consolidates the random fibers in the web, yielding a sturdy, cost-effective replacement for woven fabrics in applications such as disposables (medical masks, dental bibs, diapers, wipes, dryers sheets), semi-durables (filters, packaging, scouring pads) and durables (automotive, home furnishings, garment bags, geotextiles).

    Alliance is currently working with a major supplier of woven fabrics for various markets including healthcare. Many of their materials have a cotton and a Alliance_Calendering_Healthcaresynthetic component. The supplier wants to investigate how calendering one such blend could help reduce porosity by partially melting and sealing the surface, therefore making the material better suited for a protective garment barrier application. The supplier sent material samples to Alliance and the samples were run on a test lab calender at various speeds, temperatures, and pressures. The materials have been returned to the supplier to test results. Helping find ways to improve the material used for healthcare gear is an honor for Alliance. 

    Alliance Machine and Engraving, a member of The Bradbury Group, manufactures metal embossing machines, heated roll calenders, calendering rolls, and laminating and thermal bonding cylinders for converting paper, textiles, film, non-wovens, magnetic media, and extruded rigid and flexible plastics. Call us to see what we can do for you. 

    One Bradbury Group – working for you.

    Call +1.804.798.1199

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