Dallan, a first-person account: innovation and automation in sheet metal processing

Dallan Spa, a leading company in the design and production of automatic systems for thin sheet metal processing, has been providing complete “from coil to product” solutions for over forty years. It serves the building, furniture, appliance, and all other sectors that require high-efficiency, high-quality solutions. In this interview, CEO Andrea Dallan presents the company’s story, its strengths, and the Full Electric 120, a new roll-forming machine embodying the company’s Lean philosophy and its commitment to sustainability and intelligent automation. The discussion also touches on internationalization strategies and upcoming trade fairs.

Who is Dallan, and how did the company start?

Dallan is an Italian company founded in 1978 by Eng. Sergio Dallan. Initially established as a technical design studio, it quickly evolved into an international benchmark in the production of systems for thin sheet metal profile processing. From the beginning, Dallan stood out for its focus on profile quality and production efficiency, developing increasingly sophisticated and customized technologies.

In addition to specializing in roll forming machines, the company also manufactures complete systems for coil punching, coil-fed laser cutting, and automation solutions for profile packaging, such as the “Coil to Pack”, “Coil to Box”, and “Coil to Window” systems. Dallan has thus become synonymous with technology, precision, and innovation serving Lean Manufacturing.

What truly makes this story unique is the passion of Eng. Sergio Dallan—a drive for innovation and excellence passed down to the employees and to the new generation, today represented by me as the company CEO. This same determination and vision have allowed the company to grow, evolve, and stand out worldwide while remaining deeply rooted in its Italian heritage. The facts speak for themselves: production is entirely Made in Italy, concentrated in the headquarters of Castelfranco Veneto, which today includes four plants. An Italian excellence with a global outlook that has never forgotten its origins.

What are Dallan’s main strengths?

Dallan is recognized worldwide for its deep specialization in thin sheet metal processing (from 0.15 to 5 mm thickness), a field in which it is considered a leading reference. The company’s main strengths include:

- Tailored design and customization: from the first contact, each project is studied and analyzed in detail. Dallan does not offer standardized solutions but personalized proposals perfectly aligned with the customer’s specific needs, aiming to concretely improve production. With over 10,000 profiles developed and more than 3,000 systems installed worldwide, every phase—from design to manufacturing, shipping, and packaging, to post-sales service—is carefully managed.
- 100% Made in Italy production: all components are designed and manufactured entirely in Italy, ensuring the highest quality and reliability typical of Italian manufacturing excellence.
- Smart automation: Dallan develops automated solutions that make production processes more efficient, fast, and precise, significantly increasing overall plant productivity.
- Lean Manufacturing focus: Dallan plants are designed to maximize material use, minimize waste, optimize cycle times, and reduce energy consumption, contributing to more sustainable and cost-effective production.
- Highly qualified technical team: over 190 specialized professionals with interdisciplinary skills in mechanical, electronic, and digital fields ensure state-of-the-art solutions.
- Connected and integrated technologies: Dallan systems are fully compatible with Industry 4.0 and 5.0 environments, offering direct connection to customers’ ERP and MES systems for smart, digitalized production management.
- Continuous customer service: Dallan support continues beyond delivery, providing both on-site and remote assistance to ensure constant reliability.

What are the latest technological innovations from Dallan?

In 2025, Dallan introduced its latest innovation: the Full Electric 120 technology. The new Dallan Full Electric 120 roll former represents the perfect synthesis of advanced industrial design, full-electric technology, and lean philosophy.

This new roll-forming system is entirely electric, designed for profiles up to 1.2 mm thick and speeds up to 120 meters per minute. All hydraulic cylinders have been replaced by high-efficiency electric actuators, providing:

- up to 34% energy savings compared to hydraulic systems;
- greater reliability and easier maintenance, eliminating hydraulic oil and extending tool life;
- “flying cut” with energy recovery system, where the kinetic energy of the moving carriage is reused to power services and the main motor;
- reduced environmental impact and noise.

A true revolution in terms of sustainability and energy efficiency, adapting to modern market needs through direct coil processing and a connected, flexible, and efficient architecture.

What markets does Dallan serve, and how has it established itself internationally?

Dallan serves the global markets, making its technological solutions accessible to all thin sheet metal sectors, regardless of geographic location. The company operates successfully worldwide, demonstrating strong adaptability to different production and regulatory requirements.

Dallan has established a particularly strong position in the advanced markets of Europe and North America, where demand for automation and intelligent technologies is rapidly increasing. In these contexts, companies are constantly seeking innovative solutions to enhance efficiency, reduce waste, and respond swiftly to market demands.

Dallan’s international success is built on a unique technological offering that combines productivity, flexibility, and Lean Thinking.

Dallan systems stand out because they allow:
- up to 20% raw material savings thanks to coil processing;
- up to 75% labor reduction through advanced automation;
- extremely high production speeds, up to 120 m/min;
- fast changeovers, ideal for multi-product and just-in-time manufacturing.

To ensure even greater proximity and top-tier service, Dallan’s headquarters remain in Castelfranco Veneto (Italy), but in recent years the company has opened Dallan America in Ohio, allowing for closer relationships and faster support for North American customers.

Dallan also holds major international certifications:
- ISO 9001 – Quality Management System
- ISO 14001 – Environmental Management System
- ISO 45001 – Occupational Health and Safety Management System

These certifications confirm Dallan’s constant commitment to operational excellence, environmental sustainability, and employee safety, further strengthening its global reliability.

Which upcoming trade fairs will you attend, and what technologies will you present there?

The next international events Dallan will be attending are:

1. Blechexpo, Stuttgart – late October
2. The Big 5, Dubai – late November

Blechexpo is one of Europe’s most important events for the sheet metal processing industry—a key showcase where leading market players and top professionals meet. For Dallan, attending Blechexpo reaffirms its technological leadership and ongoing commitment to innovation.

We invite visitors to Hall 1, Stand 1309, to discover our latest developments and meet our team of experts. During the exhibition, the spotlight will be on the new Full Electric 120 line.

Visitors will also discover:
- LXN solutions for coil-fed laser cutting and EXN solutions for servo-electric coil punching, where Dallan has developed strong expertise, setting the benchmark for those seeking top quality, speed, and flexibility in thin sheet metal processing;
- Complete Coil to Pack and Coil to Window automation systems, offering concrete and innovative answers to current challenges in production efficiency and sustainability, optimizing the entire chain from coil to finished packaged product.

These trade fairs will be the perfect opportunity to explore Dallan innovations and understand how its solutions can truly transform customers’ production processes. To schedule a meeting at the fair, contact the Dallan team using the provided references.