A new multi-pass hot shape rolling was designed based on a three-dimensional analysis of channel section beams in hot rolling by the finite element method. A complete production line in industry containing 13 passes in forming the section including break-down, intermediate, and finishing sequences is modeled. The output geometry and power consumption predicted by this simulation were verified against the practical data and the measured values of the production line of Zobahan Esfahan Company. Then, a sample caliber design process to achieve a specific cross section is prepared. The minimum possible number of passes consistent with the parameters affecting the spread is the main strategy of the new caliber design. Again this new caliber design is simulated using an explicit finite element code. The geometry and dimensions of the exit cross section, the separation force, roll torques, and the power consumption in each stage are calculated. Comparison of the new roll pass parameters and that of the conventional ones in industry is made to demonstrate the advantages of the new caliber design.