By Karen Knapstein
To move coils to and from the line — without causing damage — takes equipment that’s up to the heavy-duty task. It also takes workers who have enough skill and experience to operate the equipment without causing damage or injury.
Coils come in different sizes. Weights and spool dimensions vary, but it doesn’t matter if a coil weighs 10,000 pounds or 50,000 pounds — no matter the size, coils aren’t moved by hand. Their size and weight make direct handling hazardous, so heavy equipment is used to move them.
Automated equipment is one way to reduce the risk of damage and increase efficiency. If coils are moved manually, production is held up whenever a machine may be ready, but you’re waiting for a forklift.
Jason Smoak of SWI Machinery explains that with an automated system, the process goes much smoother. Your coils are always ready to go and can be positioned to feed a machine at the touch of a button. No more waiting on moving equipment!
American Building Network, part of the Central Steel Group headquartered in Mount Airy, N.C., is one of the largest metal building manufacturers in North America. ABN’s product line includes various steel tube-framed buildings, cold-formed steel structures, and pre-engineered steel buildings. In addition to maintaining manufacturing facilities in North Carolina, Georgia, and Texas, they also coordinate with some 26 other manufacturing facilities around the country in order to meet building demand.
ABN recently updated its North Carolina manufacturing plant with automated coil-handling equipment provided by Smoak’s team. He worked with ABN to help assess their particular needs and goals, and was then able to configure an ideal system to suit.
American Building Network chose to install an automated SWI Machinery system that includes a 12-station CX-5 auto decoiling and storage system. The coils are all loaded into the system that is connected to the slitter. With the system controls, the operator is able to select the coil and the particular components to be cut from that coil. According to Smoak, “Basically, the operator says, ‘I want this coil and these are the parts I want out of that coil.’ The machine gets the coil, loads it, feeds it into the Marxman Pro slitter, and then is able to automatically produce the labeled parts on the table.” ABN also leverages an automatic labeler that applies custom barcodes to each part, for parts and process tracking.
Benefits of Using a Fully Automatic Uncoiler
Smoak reports that the CX5 is a modified, fully automatic uncoiler. In the case of ABN, the uncoiler is coupled with a Marxman Pro slitter. The system keeps track of how much material is on the coil, so the operator always knows how much stock can be run. “It measures the height of the coil, it knows the height of the mandrel, what the centerline is, and how high it’s raised.” The operator doesn’t have to physically keep track of how much coil is left on the spool; the system keeps track of that for you.
Smoak points out another benefit of the SWI machines, too; they don’t use mandrels. “Ours is able to load automatically without mandrels,” said Smoak. This is a nice feature, because a mandrel-based system requires mandrels to be placed in coils manually. So you either have to buy extra mandrels to leave in the coils, or the mandrels must be moved from coil to coil — a labor-intensive, time-intensive effort which ties up money in more equipment, and adds an extra step to the production process.
An automated system helps to minimize waste, too. “Coil steel is expensive,” as Smoak points out, “so the less scrap you produce, the better.” Coil damage incidents are minimized as well, because once the coil is loaded into the system, it doesn’t have to go back into shop storage. The coil stock comes in, is loaded into the automated system, and can be completely run through production without ever having to go back into the warehouse.
With a legacy system, there’s an additional risk of damage every time a coil has to be moved. Coils can be damaged by forklift tines, and can also get scraped or bumped while out on the storage area floor. And as anyone in the business can tell you, any damaged coil material has to be cut off and scrapped before you’re then able to produce the pieces that are needed.
Smoak summed it up by saying, “Automated system coils are accessible all the time, and there’s very little damage.” And there’s another added benefit that comes along with using an automated system, too: less required labor. An automated system only requires a single operator, rather than the two or three you’d have to employ in order to support a manual coil moving system.
Smoak Impressed with ABN
After working with American Building Network on their recent SWI Machinery upgrade project, Smoak was definitely impressed by the company. “They’re pretty innovative guys,” Smoak said. Some examples of innovation he noted include the fact that ABN videos building installations for further training purposes, uses drones to gather footage from all angles, and is proactive with their use of social media. “They’re certainly forward-thinking,” observes Smoak. “They’re innovative guys, and that follows to their use of innovative equipment in the shop.” RF
americanbuildingnetwork.com
In the demanding world of steel manufacturing and processing, efficient material handling is not just a convenience—it’s a critical operational necessity. Coil handling equipment represents the backbone of modern steel logistics, enabling the safe and efficient movement of massive steel coils throughout production facilities. At MORELLO, we’ve dedicated decades to perfecting customized solutions for the steel industry’s most challenging material handling requirements.
Our specialized coil handling equipment is engineered to address the unique challenges faced by steel foundries, fabricators, and processors operating in extreme environments with loads ranging from 10 to hundreds of tons. Understanding the complexities of steel intralogistics has positioned us as a trusted partner for industrial operations worldwide, where productivity, safety, and operational efficiency cannot be compromised.
The steel industry presents unique challenges when it comes to material handling, particularly with heavy steel coils that can weigh anywhere from 10 to 35 tons or more. Modern coil handling equipment has evolved significantly to address these demanding requirements, incorporating advanced safety features, precision control systems, and robust structural designs. At its core, effective coil handling equipment must provide secure transport while preventing damage to valuable materials.
Steel coil cars, saddle-rest systems, and specialized lifting mechanisms form the foundation of comprehensive coil handling solutions. These systems must operate reliably in harsh environments characterized by extreme temperatures, metallic dust, and continuous operation schedules. The integration of these handling systems with plant-wide logistics networks has become increasingly important as manufacturers seek to optimize production flow and minimize downtime.
For steel processors and fabricators, the selection of appropriate coil handling equipment directly impacts operational efficiency, worker safety, and product quality. Modern systems incorporate features such as:
As steel manufacturing facilities continue to prioritize operational efficiency and workplace safety, the demand for sophisticated coil handling equipment has grown substantially. These systems represent a critical link in the production chain, enabling the smooth flow of materials through processing stages while minimizing handling damage and operational interruptions.
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The steel industry faces several critical challenges when managing coil logistics within manufacturing environments. According to industry experts, unsecured material handling ranks among the top supply chain concerns, alongside material shortages, demand fluctuations, and rising operational costs. These challenges directly impact productivity, safety, and ultimately, profitability.
Steel coils present unique handling difficulties due to their massive weight, cylindrical shape, and susceptibility to damage. A single steel coil can weigh between 10-35 tons, making proper support and balance essential during transport. Even minor mishandling can result in costly material damage or, worse, catastrophic accidents that endanger personnel.
Environmental factors further complicate coil handling operations. Steel facilities typically operate in harsh conditions with extreme temperatures, airborne particulates, and space constraints. Equipment must withstand these challenging environments while maintaining precise operational capabilities.
MORELLO’s approach to addressing these challenges includes:
The implementation of purpose-built coil handling equipment delivers significant operational benefits, including enhanced workplace safety, reduced material damage, improved process flow, and decreased downtime. By addressing these fundamental challenges with engineered solutions, steel manufacturers can optimize their internal logistics while supporting their decarbonization initiatives through electric transport systems.
The evolution of coil handling equipment has been accelerated by the integration of cutting-edge technologies that enhance performance, safety, and operational efficiency. Modern systems now incorporate sophisticated features that transform traditional material handling into intelligent, connected operations that support Industry 4.0 initiatives.
Lithium battery technology represents one of the most significant advancements in coil handling equipment. These power systems enable continuous operation with rapid recharging capabilities, eliminating the downtime associated with traditional power sources. More importantly, they support facility decarbonization efforts by providing zero-emission alternatives to diesel-powered equipment, creating cleaner work environments while reducing the carbon footprint of steel operations.
Software integration has become equally crucial in advanced coil handling systems. RFID transponders, real-time location systems, and automated routing protocols allow coil cars to navigate precisely to designated positions without manual intervention. This integration extends to plant-wide management systems, creating a seamless flow of information that optimizes material movement throughout the facility.
Precision hydraulic systems now provide exceptional load control, allowing operators to position heavy coils with millimeter accuracy. Omnidirectional movement capabilities enable navigation in tight spaces, eliminating the constraints of traditional fixed-path systems. Enhanced safety features, including proximity sensors, automatic braking systems, and operator warning indicators, have dramatically improved workplace safety standards.
For steel manufacturers seeking to modernize their operations, these technological advancements offer compelling advantages in terms of operational efficiency, workplace safety, and environmental sustainability. The implementation of AGVs in manufacturing environments represents the next frontier, enabling fully autonomous material handling that further reduces labor requirements while enhancing precision.
MORELLO’s expertise in coil handling equipment is best illustrated through real-world implementations across diverse steel operations worldwide. These case studies demonstrate how customized solutions address specific operational challenges while delivering measurable improvements in efficiency, safety, and productivity.
In Mexico, a major steel coil manufacturing facility faced logistical challenges moving coils weighing up to 35 tons through their production process. MORELLO engineered specialized coil cars with custom saddle rests designed to cradle the cylindrical loads securely during transport. The system’s integration with the plant’s operating software created a synchronized material flow that significantly reduced handling time and eliminated damage incidents. The implementation transformed their internal logistics, creating a seamless process from production to storage.
A different approach was required for a Texas-based steel tube manufacturer that needed to move SRM mill stands weighing up to 65 tons. The solution involved a sophisticated heavy-duty trolley system using rail carts capable of moving multiple mill stands simultaneously in both parallel and perpendicular directions. The integration of RFID technology enabled precise positioning of each component, creating an intelligent material handling system that adapted to changing production requirements.
Steel foundries worldwide have benefited from MORELLO’s electric scrap bucket carts, which represent the cutting edge of steel scrap handling technology. These lithium-battery powered systems operate continuously in extreme foundry environments, eliminating pollution while providing reliable 24/7 material transport. The implementation of these systems has supported decarbonization initiatives while improving operational reliability.
Each case demonstrates how purpose-built coil handling equipment addresses the unique requirements of different steel operations. The common thread across these implementations is the meticulous attention to specific operational needs, environmental conditions, and safety requirements that characterizes MORELLO’s engineering approach.
The evolution of coil handling equipment continues to accelerate as manufacturers like MORELLO push the boundaries of what’s possible in heavy material transport. Looking ahead, several key trends are shaping the future landscape of steel coil handling technology, creating opportunities for unprecedented efficiency and operational excellence.
Autonomous systems represent perhaps the most transformative development in coil handling. The integration of AGVs in manufacturing environments is revolutionizing how steel producers move materials through their facilities. These self-navigating vehicles eliminate the need for dedicated operators while providing consistent, precise material placement. Advanced sensor arrays enable these systems to adapt to changing floor conditions and avoid obstacles, creating a dynamic material handling solution that responds to real-time production requirements.
Sustainability has become equally important in modern coil handling equipment design. Beyond the emissions benefits of electric propulsion, newer systems incorporate energy recovery features that capture braking energy and return it to the battery system. This approach extends operational range while reducing overall energy consumption, supporting broader corporate sustainability initiatives while lowering operational costs.
Predictive maintenance capabilities are transforming equipment reliability. Modern coil handling systems incorporate comprehensive monitoring systems that track component performance, hydraulic pressures, motor temperatures, and battery health. This data feeds into analytical platforms that can predict potential failures before they occur, enabling preventative maintenance that minimizes costly downtime.
For steel manufacturers looking to maintain competitive advantage, investing in these advanced coil handling technologies offers substantial benefits. Beyond the immediate operational improvements, these systems create the foundation for future facility optimization, data-driven decision making, and enhanced workplace safety. As the steel industry continues to evolve, sophisticated coil handling equipment will remain a critical component of successful operations.
The efficient movement of steel coils represents a critical operational challenge for manufacturers worldwide. As we’ve explored, specialized coil handling equipment provides the foundation for safe, efficient, and sustainable material transport in even the most demanding industrial environments. MORELLO’s decades of expertise in designing and manufacturing custom material handling solutions has positioned us as a trusted partner for steel producers facing complex logistical challenges.
Our approach combines engineering excellence with deep industry knowledge, resulting in coil handling systems that deliver measurable operational benefits while supporting broader sustainability goals. Whether you’re managing a steel foundry, fabrication facility, or processing plant, our team can develop a tailored solution that addresses your specific requirements.
The company is the world’s best Coil Handling Equipment supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.