Capabilities
Manufacturing capabilities
Roll forming, sheet metal forming and custom-designed machines, from six plants across India.
- 27roll forming mills (all locations)
- 0.5 – 8.0 mmstrip thickness range
- 10 – 1,800 mmcoil width range
- 3,000 MTmonthly rolling capacity
Core process
Cold roll forming
Cold roll forming is our specialisation. A continuous strip passes through a series of roll stations. Each pair of contoured rolls bends the strip a little further, until it reaches the finished cross-section. The metal is formed at room temperature, so the profile stays uniform along its full length.
The process suits long parts with complex cross-sections, including door sashes, glass run channels, drip rails and reinforcements. Lips, returns and hems can all be formed into a single section.
- Strip feed. Strip of the specified material, width and thickness enters the line.
- Progressive forming. Successive roll stations shape the strip step by step.
- Finished section. The profile leaves the last station at its final cross-section.
- Cut to length. Profiles are cut to the length the application requires.
Roll forming mills & capabilities
27 roll forming mills
- Roll forming mills
- 27 (all locations)
- Thickness range
- Min 0.5 mm to max 8.0 mm
- Coil width range
- Min 10 mm to max 1,800 mm
- Monthly rolling capacity
- 3,000 metric tonnes
What we can do for you
Roll formed profiles
Open and closed sections for automotive, HVAC, construction and electrical uses.
Sheet metal forming
Formed metal components, including bumpers, reinforcements and panel sections.
Development to drawing
New profiles developed from the customer's drawing for a specific programme.
Custom-designed machines
Machines for the sheet metal forming industry. More about our machines.
Raw material
We roll form the following raw material grades:
- Cold rolled (CR) and hot rolled (HR) steel in grades D, DD, EDD, HSLA, GA
- Austenitic stainless steel (301–304)
Monthly rolling capacity: 3,000 metric tonnes.
Tell us the material, grade, thickness and finish your drawing specifies, and we will confirm feasibility.
Quality & engineering
Star Auto Industries has a 48-year track record of quality manufacturing processes. Every certified location holds IATF 16949, and our Dharwad plant also holds ISO 9001, ISO 14001, ISO 45001 and EN 15085 for railway welding.
Each profile in our catalogue is documented as a dimensioned cross-section drawing, showing radii, flange dimensions and drawing scale.
Frequently asked questions
What is cold roll forming?
Cold roll forming is a continuous process. A metal strip is bent gradually by successive pairs of contoured rolls until it reaches the required cross-section. It is done at room temperature and gives long, uniform profiles.
Which materials can Star Auto Industries roll form?
We roll form cold rolled (CR) and hot rolled (HR) steels in grades D, DD, EDD, HSLA and GA, and austenitic stainless steel (301–304).
What thickness and width can you roll form?
Our mills handle strip from 0.5 – 8.0 mm thick and coil widths from 10 – 1,800 mm.
What is your production capacity?
We have 27 roll forming mills across our six plants, with a monthly rolling capacity of 3,000 metric tonnes.
Can you develop a new profile for our part?
Yes. Most of our profiles have been developed to customer drawings for a specific vehicle or equipment programme. Send your drawing and requirements through the enquiry form.
Have a profile drawing or a component requirement?
Send us your drawing, material and quantity. Our team will review it and get back to you.