Eliminate metal fabrication delays – Faccin’s high-precision plate rolling solutions deliver flawless bends

GRW Engineering, a prominent South African manufacturer of tankers and trailers, has long been recognised for its innovation and quality in serving industries such as petroleum, chemical, construction, mining, and general freight. Operating from a state-of-the-art facility in Worcester, Western Cape, GRW delivers transport solutions to markets across Southern and Eastern Africa, Australia, the UK, and Europe. To maintain its competitive edge and meet increasing production demands, GRW identified a critical need to improve efficiencies in its tank and trailer assembly process. Traditionally reliant on welding and rolling multiple metal plate segments to form full-length shells, this method proved time-consuming, labour-intensive, and limited in consistency. In response, GRW made a strategic investment in advanced plate rolling technology from Faccin to streamline operations, enhance quality, and future-proof its manufacturing capabilities.

About GRW Engineering: GRW Engineering was established in 1995 by brothers Gerhard and Wentzel van der Merwe, along with business associate Rossouw van Eeden, and is a prominent South African manufacturer of tankers and trailers, headquartered in Worcester in the Western Cape. GWR is one of South Africa’s premier construction and engineering companies with over 50 years of experience transforming landscapes and building critical infrastructure. More about GRW Engineering

Challenge

GRW Engineering’s production process involved joining shorter plate segments to form the 12-metre shell lengths required for tanker and trailer builds. These segments had to be welded and rolled individually, increasing production time and introducing complexity and inefficiencies on the shop floor. Given the diverse material requirements—from 3mm to 16mm aluminium and 2mm to 5mm stainless steel—the need for precision and consistency was paramount. GRW produces tanks in both conical and cylindrical forms, with diameters ranging from 1,800mm to 2,600mm, depending on volume and application. The lack of a single-process solution to roll full-length shells in one pass created bottlenecks, required extensive manual handling, and impacted the overall throughput of the facility. As GRW scaled production to meet global demand—including a busy weekly output of up to 34 custom trailers—the team needed a reliable, high-performance rolling system that could reduce lead times, improve material handling, and increase safety and efficiency in the production process.

Solution

GRW Engineering invested in the Faccin 4HEL 12-metre CNC plate roller to address these challenges, supplied and installed by Talmac Machine Tools. This advanced rolling solution enabled GRW to roll an entire 12-metre metal envelope in one seamless process, eliminating the need to join multiple smaller segments. The Faccin 4HEL 12-metre CNC plate roll offered precision, repeatability, and adaptability to work with a wide range of materials and thicknesses.

With this new machine, GRW could now fabricate full-length barrels efficiently, attach dish ends with minimal effort, and pass the assemblies downstream for final production—all within the same workflow zone. This dramatically reduced production time, lowered error rates, and improved the structural integrity of the final product.

The new roller complements other high-end equipment in GRW’s facility, including CNC laser cutters and a custom-built Friction Stir Welding (FSW) system developed in partnership with Nelson Mandela University. Together, these technologies reflect GRW’s ongoing commitment to advanced manufacturing and continuous improvement.

Implementation

GRW began preparations for the new Faccin plate roller by redesigning part of its production facility. Foundation work was completed in late 2024, and the machine—measuring 12m in length and weighing over 131 tons—was installed at the beginning of 2025. To optimise workflow and align material handling across the production line, the roller was recessed 900mm into the floor to match the level of GRW’s existing production tables and friction stir welding station.

From the moment of commissioning, the machine was integrated into GRW’s manufacturing processes with minimal disruption. Production teams were trained on the new system, and workflows were adjusted to accommodate the improved throughput. The roller has significantly improved operational efficiency, allowing full shell lengths to be produced in one pass and enabling downstream processes—such as dish-end welding and flaring—to be carried out faster and with greater consistency.

This upgrade, combined with in-house capabilities in rolling, dish-end fabrication, and friction stir welding, has enhanced GRW’s ability to meet international standards including ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road) compliance.

Conclusion

With the installation of the Faccin 4HEL 12-metre CNC plate roller, GRW Engineering has transformed a critical part of its production process. The new equipment has enabled the company to enhance product quality, shorten lead times, and improve manufacturing efficiencies—all while maintaining the flexibility to meet the highly customised needs of its clients across multiple continents. As demand for high-performance transport equipment continues to grow, GRW is now better positioned than ever to deliver on its promise of quality, innovation, and reliability.

Is your manufacturing operation limited by inefficient rolling processes or outdated forming equipment?

Contact our Headland Technology and Faccin experts to explore how advanced rolling solutions can streamline your production, reduce waste, and drive measurable business outcomes across Australia and New Zealand.