FFX Technology for tube mill lines represents a significant advancement in the machinery and automation used in tube production. This technology, known as Flexible Forming Technology, allows for the efficient and precise shaping of tubes from flat metal sheets. Unlike traditional methods that often require extensive manual adjustments and setup times for different tube sizes and shapes, FFX Technology enables a more streamlined and automated process.

This automation not only reduces production time but also minimizes human error, leading to a consistent and high-quality output. The integration of FFX Technology into tube mill lines offers numerous benefits.

ZTF(FFX) Flexible Forming Tube Mill

FFX, or Flexible Forming System, is a state of the art tube forming technology. Unlike traditional ERW systems, which require changing forming rolls to adjust the tube diameter or shape, FFX uses specially designed tooling that allows for quick mechanical adjustments. This means that the tube size and shape can be changed without stopping the production line and in the shortest time possible.

In essence, FFX is a fully modular and intelligent system that enables the production of round, square, and rectangular tubes using a single shared production line. This results in significant savings in time, space, costs, and manpower.

How FFX Technology Enhances Tube Mill :

Although the ERW Tube Mill system is still used in some production lines, the FFX system is a strategic and forward-thinking choice for factories aiming to increase productivity, reduce downtime, produce a variety of products, lower operational costs, and expand their export markets.

At Lotos Forming, we help our clients stay one step ahead in the industrial competition by designing and manufacturing FFX production lines based on the latest global technologies.

Advantages of Using the FFX System in Tube Production:

Reduced Size Changeover Time: Quick size adjustments without stopping

the production line

•  Tooling Cost Savings: One-time investment in FFX tooling

•  Increased Production Speed: Minimized downtime and enhanced

productivity

•  Accurate and Automated Control: Compatible with PLC systems and

centralized control

Consistent Tube Quality: Stable and uniform output across all production

batches

Main technical parameters:

1. Uncoiling

2. Shearing and Butt-Welding

3. Material Accumulating

4. Non-Power Leveling

5. Mill Forming (Initial Forming)

6. High-Frequency Welding

7. Removing Burrs from the Outside of the Weld Seam

8. Zinc Spraying with Molten Zinc

9. Cooling

10.Sizing

11.Rough Straightening 12.Fixed-Length Cutting 13.Run-Out Table

The Role of FFX Technology in Tube Mills:

The FFX (Flexible Forming System) developed by Lotos Forming is recognized as one of the most advanced and flexible tube production technologies in the industry. This system allows manufacturers to easily change tube sizes and shapes without the need to replace roll sets, significantly increasing both productivity and production speed.

Moreover, the FFX system minimizes roll maintenance costs, production downtime, and the need for highly skilled labor, making it a strategic choice for factories and manufacturers seeking operational efficiency.

At Lotos Forming, we design and deliver fully customized FFX production lines tailored to each customer’s specific needs, using cutting-edge global technologies. For improved performance, reduced costs, and enhanced production quality, FFX is the ultimate solution.

For expert consultation and the best tube mill solution, contact our specialists today

1- What is the production capacity of the FFX tube mill line?

Depending on the tube specifications, the production speed can reach up to 120 meters per minute.

2- Is tube size adjustment automated in the FFX tube mill line?

Tube size adjustment is performed in a semi-automatic manner. It involves replacing or adjusting the rollers according to the new tube size, allowing for quicker and more efficient size changes compared to traditional systems.

3- Can pressure testing or ultrasonic testing equipment be integrated into the FFX line?

Yes, upon customer request, it is possible to integrate additional equipment such as hydrostatic pressure testing, ultrasonic weld inspection, or end facing & beveling machines into the FFX tube mill line.

4- Do FFX tube mill lines from Lotos Forming come with warranty and international after-sales service?

Yes, all FFX (Flexible Forming System) tube mill lines provided by Lotos Forming come with a 12 to 24-month warranty, covering technical failures due to manufacturing defects and system-related issues. We also provide comprehensive international after-sales service, including support for installation, commissioning, and long-term operation, delivered by our experienced technical team.
5- What does the after-sales service of Lotos Forming include for FFX systems?

Lotos Forming’s after-sales service for FFX lines includes:

 Installation and commissioning

• Operator training
• Preventive maintenance
• Spare parts supply
• Technical consultation

Our service team is available 24/7 to offer both online and on-site support, ensuring your production line remains efficient and fully operational.

6- What services are covered by the warranty for FFX lines?

• The FFX system warranty covers:
•  Replacement of defective parts
• Free repair services within the warranty period
• Remote and on-site technical support

Our dedicated after-sales service team ensures quick response times to minimize downtime and resolve any operational issues effectively