How Alloy Coil Packing Line resolve the problem for service center

For Alloy Slit Coil Packing at Singapore Service Center, Connected to the Slitting Line

Problems Facing the Customer's Factory

1. Packing Speed Slow

One of the major issues faced by the customer’s factory is the slow packing speed. The manual packing process is time-consuming and heavily reliant on crane operations. Coils must be moved multiple times with the crane, from the slitting line to the packing area, which creates bottlenecks in production. The crane is often occupied with moving coils for packaging, which limits its availability for other tasks, causing delays in the overall production process. As a result, the factory faces challenges in maintaining consistent throughput, leading to inefficiencies and increased labor costs. Automating the packing process would free up the crane, allowing it to be used for other essential operations, improving overall productivity.

2. Safety Concerns

Safety is a critical concern in the customer’s factory, especially during coil packing, stacking, and moving operations. The manual handling of heavy alloy slit coils poses significant risks to workers, increasing the potential for accidents or injuries. During packing, workers must often maneuver around moving coils, which can be hazardous. Similarly, stacking coils manually increases the likelihood of instability, raising the risk of coils falling and causing damage or injury. Additionally, the use of cranes to move coils in a crowded space can lead to unsafe working conditions. Automating these processes would greatly improve safety, reducing the reliance on manual labor and minimizing the risks associated with coil handling.

3. Packing Quality Control

Maintaining consistent packing quality is another challenge the factory faces. Manual packing often results in inconsistencies in how coils are wrapped and strapped, leading to variations in protection during transit. Some coils may not be securely packed, increasing the risk of damage during storage or transportation. Additionally, manual packing does not always provide uniform tension when wrapping, which can compromise the structural integrity of the packaging. Poor quality control in packing leads to increased returns, customer dissatisfaction, and potential financial losses. An automated packing system would ensure consistent quality, with precise wrapping and strapping that protects the coils from external factors and guarantees safe transportation.

Conveyor System for Coil Moving

A conveyor system is the most efficient solution for moving alloy slit coils throughout the packing process. Designed to handle coils with widths between 10-200mm, weights of 50-800kg, and outer diameters ranging from 800-1600mm, the conveyor minimizes the need for crane usage. By automating the movement of coils from the slitting line to various packing stations, this system ensures continuous, smooth operations, reducing delays and manual handling. Coils can be transferred quickly and safely, allowing the facility to increase its overall packing speed and reduce the dependence on cranes, freeing them for other essential tasks in the production line.

Automatic Wrapping Machine

The automatic wrapping machine is essential for ensuring consistent and efficient packaging. This machine can accommodate coils of varying dimensions and applies precise tension to the wrapping material, securing the coil for transit. The automated process eliminates manual wrapping errors and ensures uniform protection across all coils. With the ability to wrap coils in under 30 seconds, this system increases productivity while improving the safety and quality of the packaging. It guarantees that each coil, regardless of size, is securely wrapped, protecting it from dust, moisture, and damage during transport and storage.

Coil Down Ender for Coil Pick Up and Turning

The coil down ender is crucial for safely picking up and turning coils after they have been processed. It turns coils from an eye-to-sky to an eye-to-wall position, allowing for easy wrapping and further handling. By automating this process, the system reduces manual labor and improves safety, particularly for larger coils with diameters up to 1600mm and weights of up to 800kg. This precise turning mechanism ensures that coils are properly positioned for the next stage of packaging, increasing both speed and safety in the production line.

Coil Stacking

The coil stacking system is designed to streamline the organization of coils after they are packed. It automatically places coils in neat stacks, up to five high, optimizing floor space and improving storage efficiency. This system reduces manual handling, which not only speeds up the process but also ensures that coils are stacked safely and securely. By automating the stacking process, the risk of human error and coil damage is minimized, enhancing both productivity and safety in the warehouse.

Vacuum Solution for Stacking Without Timber Spacer

The vacuum solution for stacking offers a modern alternative to traditional stacking with timber spacers. Using vacuum suction technology, this system lifts and stacks coils without the need for additional spacers, allowing for more efficient use of space. This is particularly useful for coils with smaller widths (as low as 10mm) and larger outer diameters. By eliminating the need for timber spacers, the vacuum solution reduces material costs and handling time while ensuring that coils are securely and precisely stacked, providing a cleaner and more organized storage environment.

Turntable for Coil Packing and Strapping

The turntable solution facilitates both the packing and strapping of coils by turning them into optimal positions for automated strapping and wrapping tools. This tool allows coils to be rotated during the packing process, ensuring that each coil is positioned precisely for both strapping and wrapping. It eliminates the need for manual coil handling, enhancing safety and efficiency, especially when handling coils with varying dimensions. By incorporating the turntable into the packing line, the overall process becomes more fluid and consistent, ensuring each coil is securely packed and ready for transport.


 

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