Difference Between 3 Roll Plate Bending/Rolling Machines & 4 Roll Plate Bending/Rolling Machines

Overview

Here are the 5 main differences between a 3-roll vs a 4-roll plate bending machine: 

• Process: A 3-roll machine requires manual plate turning; a 4-roll bender is a single, automated process.

• Precision: 3-roll benders can leave flat ends; 4-roll machines guarantee perfect cylindricality.

• Speed: A 3-roll machine is slower due to manual steps; the 4-roll variant is faster for high-volume work.

• Labor: 3-roll benders need more operator involvement; 4-roll machines minimize manual handling.

• Cost: 3-roll machines have a lower initial price; 4-roll benders require a higher investment but also offer better ROI.

Check out the complete blog for a detailed breakdown of the differences between 3-roll and 4-roll benders!

Should I choose a 3-roll plate bender or go with a 4-roll plate rolling machine?

If that’s the question you are dealing with, you’ve come to the perfect blog post!

I work for Himalaya Machinery, where we have been producing metal-bending and working machines for more than 3 decades.

And in this guide, I am going to discuss 5 major differences between 3-roll vs 4-roll plate bending or rolling machines.

I have also included a table of differences showing the major distinctions between the two machines. 

So, if you are in a hurry, just scan through it to find out which machine you should choose!

3 Roll vs 4 Roll Plate Rolling/Bending Machines: Table of Contents

• 3 Roll vs 4 Roll Plate Rolling/Bending Machines: Table of Differences

• What is a 3-Roll Plate Rolling Machine?

• What is a 4-Roll Plate Rolling Machine?

• What are the Major Differences Between 3 Roll vs 4 Roll Plate Rolling Machines?

• 3 Roll vs 4 Roll Plate Rolling/Bending Machines: Final Verdict

• 3 Roll vs 4 Roll Plate Rolling/Bending Machines: FAQs
  

3 Roll vs 4 Roll Plate Rolling/Bending Machines: Table of Differences

In a hurry? 

I’ve got you covered! 

Here’s a table covering the 5 main differences between the two machines: 

What is a 3-Roll Plate Rolling Machine?

A 3-roll plate rolling machine is a piece of industrial equipment that we use to bend metal sheets into shapes like curves and cylinders.

As its name suggests, it has 3 rolls: 

• One roller on the top.

• Two rollers at the bottom. 

The working principle of 3-roll plate benders can be summarised by their “pinch action”.

The 1 roll on top presses down on the metal sheet against the 2 rollers at the bottom. 

Here’s the key: the metal sheet is pushed through the rollers.

So, you can use the cylindrical shape of the roller along with the appropriate pressure and directional settings to bend or roll the metal sheet into different shapes. 

The major factor that you can adjust to determine the shape of the metal sheet is the position of the 2 rolls at the bottom. This will determine the radius of the bend or curvature!

One structural drawback of 3-roll benders is that you only get a one-way bend action. 

That is, you cannot bend the plate on two sides: it has only one roller (the top roller) that does the bending, whereas the two at the bottom act as crucibles. 

So, if you want to bend a plate from two sides, you will have to turn it around manually!

Why Use 3-Roll Plate Rollers?

3-roll benders offer you some advantages that a 4-roll plate roller (as we will see) cannot: 

• It is much easier to operate due to its straightforward working mechanism.

• Usually more affordable compared to a 4-roll plate roller.

• Is much more compact compared to a 4-roll machine. 
  

3-Roll Machine Use Cases

All of these qualities and characteristics make 3-roll plate rollers ideal for: 

• General fabrication.

• Creating pipes with large diameters.

• Manufacturing storage tanks.

• Producing structural cylinders for construction.

Next, let’s take a quick look at a 4-roll machine, its qualities, and use cases.

What is a 4-Roll Plate Rolling Machine?

A 4-roll plate rolling machine is a plate-bending machine with 4 rollers that gives you greater control and efficiency in bending operations. 

The benefits of a 4-roll bender come from its component parts: 

• A top roller and a bottom roller: these are the main drivers of the machine.

• Side rollers: these are the crucial addition over 3-roll benders.

As a result of the architecture of a 4-roll bender, what you get is an “enclosed action” instead of a “pinch action”.

That is, a 4-roll plate roller helps you grip a metal plate from all four sides rather than just two (top and bottom), which is the case with 3-roll benders.

With the enclosed action, you can bend a metal plate on both sides without having to turn it around manually!

Why Use 4-Roll Plate Rollers?

4-roll plate benders have very specific advantages: 

• They can help you create “perfect circles” with metal sheets.

• The enclosed action offers more efficiency compared to manual pre-bending.

• Your metal sheets won’t suffer from flat ends as they do with a 3-roll machine.

• 
  

4-Roll Machine Use Cases

4-roll plate rollers are typically used for: 

• Operations that need high-volume production.

• Any application that needs precision.

• Industries where perfect cylindrical shapes and flat-free ends are non-negotiable.

Now, let’s discuss the major differences between 3-roll and 4-roll plate-bending machines. 

What are the Major Differences Between 3 Roll and 4 Roll Plate Rolling Machines?

There are 5 major differences between 3-roll vs 4-roll plate benders: 

• Bending Process & Operation

• Precision & Final Part Quality

• Automation & Operator Workflow

• Productivity & Output Speed

• Investment & ROI

Let’s explore them one by one: 

1. Bending Process & Operation

The major difference between 3-roll and 4-roll benders is that the former requires extra, manual steps for perfect bends: 

• 3-Roll Plate Bender: You will have to follow a multi-step process. First, pre-bend one end. Then, manually feed the plate in so you can pre-bend the second. Lastly, you can feed the plate in, and it will be rolled into a cylinder. But you might end up with some flat ends!

• 4-Roll Plate Bender: The operation is much smoother. All you have to do is feed the plate in. The enclosed action will ensure that your plate is pre-bent and then bent into a perfect curve in one integrated process. 

Key Takeaway: If you need to produce large volumes of bent metal sheets or cannot afford any flat ends at all, use a 4-roll machine. In all other cases, a 3-roll bender will get the job done. 

2. Precision & Final Part Quality

The next major difference between the types of rolling machines is the accuracy of the final results. 

• 3-Roll Plate Bender: The pinch action supports highly accurate curvatures and bends. But this depends highly on the amount of skill, time, and dedication you put into each operation and bend. 

• 4-Roll Plate Bender: These offer a much higher degree of precision and accuracy. They are perfect for producing perfect curves and circularity. 

Key Takeaway: If you want a very high degree of accuracy and precision without putting in manual effort or leaving the final shape up to dedication every single time, go for 4-roll machines. If small flatpots are acceptable, a 3-roll machine will work just fine. 

3. Automation & Operator Workflow

When it comes to automation, there is a clear winner: 

• 3-Roll Plate Bender: Supports limited automation because you will have to turn the plate to pre-bend the second end of the metal sheet. Plus, you will also have to operate a swing arm to remove the plate from the machine. 

• 4-Roll Plate Bender: Offers more scope for automation. It will pre-bend both ends of a sheet on its own, and the final product can be unloaded straight through the rolls. 

Key Takeaway: If you need a plate roller for CNC integration or need to minimise labour costs while getting higher throughput, you will need a 4-roll bender. If the workflow speed and labour costs are not your biggest concerns, go with a 3-roll plate roller.

4. Productivity & Output Speed

This is another category where there is a clear distinction between 3-roll vs 4-roll plate bending machines: 

• 3-Roll Plate Bender: Slower process compared to a 4-roll bender; it requires more steps + manual intervention.

• 4-Roll Plate Bender: Much faster process - all you have to do is feed the plate, and the integrated process will take care of the rest!

Key Takeaway: For low-volume requirements or shop jobs, I suggest going with a 3-roll plate bender. If you need to produce high volumes, the speed of your plate bender can make the difference between you meeting a deadline and missing it! So, for these, use a 4-roll machine.

5. Investment & ROI

Lastly, we get down to the brass tacks. Let’s see which machine will cost you more, and if it’s worth it: 

• 3-Roll Plate Bender Price: It costs less compared to a 4-roll plate bending machine. So, if you need value-for-money, a 3-roll machine is the better option.

• 4-Roll Plate Bender Price: You will have to make a higher initial investment. But it will also give you faster throughput and reduce the requirement for manual labour. 

Key Takeaway: If you need an affordable option to achieve short-term targets or fulfil low-volume orders, choose the 3-roll machine. If you need a machine that will give you good returns in the long term, I recommend a 4-roll plate bender. 

3 Roll vs 4 Roll Plate Rolling/Bending Machines: Final Verdict

Both 3-roll and 4-roll plate rolling and bending machines have their own strengths and weaknesses. 

So, which one should you choose? 

My final recommendation: 

First, evaluate your needs: 

• Do you really need a completely integrated process for sheet bending? 

• Does your industry, function, or customer require extremely precise finishing? 

• Can you afford to invest for the long term?

If your answers to all three questions are “Yes!”, go for a 4-roll plate rolling machine. 

If your answer is “Not really…”, you can’t go wrong with a 3-roll plate rolling machine!

Still not sure which machine is right for you?

Get in touch with us!

At Himalaya Machinery, we specialise in manufacturing tailored 3 and 4-roll plate rolling and bending machines for a wide range of industries.

Whether you need them to produce regular bends, oil tankers, aerospace equipment, or non-elliptical shells, we have the experience to help you choose the right machine and the expertise to manufacture a machine to your specifications!

3 Roll vs 4 Roll Plate Rolling/Bending Machines: FAQs

1. What is the biggest operational difference between a 3-roll and a 4-roll machine?

A 3-roll machine requires manually turning the plate to pre-bend both ends, while a 4-roll machine does it automatically in one step, saving time and labor.

2. Will a 3-roll machine leave flat ends on my cylinders?

Yes, unless the operator skillfully pre-bends both plate ends, a standard 3-roll machine can definitely leave small flat sections. A 4-roll machine is designed to eliminate them entirely.

3. Is a 4-roll machine always the better choice?

Not always! If you have a limited budget, lower production volume, or can tolerate minor flat ends, a 3-roll machine offers excellent value and capability.