Automation of Unloading and Counting of Galvanized Profiles
Client
National manufacturer of plasterboard systems
Location
Italy
Sector
Metallurgical Industry / Construction
Critical process
Unloading, counting, and stacking of galvanized sheet metal profiles
The Initial Problem
The production of plasterboard profiles occurs at high speeds. The management system downstream of the roll former presented critical issues that limited the entire plant:
- Bottlenecks and Downtime: The need to ensure a continuous cycle was hindered by manual unloading management, which struggled to keep pace with the roll former.
- Labor Inefficiency: The process required the constant use of at least 2 operators engaged in extremely repetitive and exhausting work.
- Counting Errors and Fatigue: Monotony and physical/mental fatigue inevitably led to errors in counting pieces for each pack, resulting in complaints or logistical problems.
The Neomec Solution
Given the specificity of the product, Neomec developed a custom prototype dedicated to automatic unloading and stacking:
- Integrated Automation: The system receives the profiles exiting the roll forming machine, counts them electronically, and stacks them in an orderly manner.
- Continuous Cycle and Pack Change: The machine manages the transition between a completed pack and the next one without requiring the roll former to stop.
- Masked Time Operation: The system design allows the operator to complete secondary operations (such as strapping) while the machine continues to produce the next pack.
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Quantifiable Results and Benefits
The introduction of the Neomec prototype transformed the production line from a critical manual process to a fluid automated flow:
Labor Optimization
Dedicated personnel decreased from 2 operators to just 1. This 50% labor savings is accompanied by a less grueling role.
Total Precision (Zero Errors)
Thanks to the electronic counting integrated into the prototype, errors in the packs have been completely eliminated.
Maximum Productivity
By eliminating machine downtime related to unloading, the plant reached the milestone of a true continuous cycle.
Operator Well-being
Physical and mental fatigue related to the frantic pace of the roll former was eliminated, refocusing the operator on supervision and final strapping.
Why the client chose Neomec
The client chose Neomec for its ability to act as a technological partner rather than just a supplier, accepting the challenge to design and build a unique, customized prototype capable of adapting perfectly to the spaces and specific needs of the line.
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