The rise of automation in coil processing

By Chad Rowe, MetalForming LLC.

From the manual coil processing systems of the past to today’s highly automated warehouses, technology has dramatically transformed metalforming. 

As metal continues to rise in popularity for construction applications, contractors are adopting varying levels of automation to improve efficiency, reduce costs and streamline production. 

Coil processing systems fall into three categories. Manual systems are cost-effective but labor-intensive, requiring hands-on operation for slitting and cutting. On the other hand, fully automated systems handle everything from coil storage to cutting, reducing manual intervention to a supervisory role and ensuring seamless integration with ERP software. However, they can be a large upfront investment and require a large amount of space. Lastly, semi-automated systems fall somewhere in between – they automate repetitive tasks like knife positioning while keeping costs manageable for mid-sized contractors. 

The rise of automation 

Historically, coil processing was limited to large manufacturers due to high costs. However, in 1998, MetalForming LLC and Schlebach introduced a more affordable slit-to-width and cut-to-length machine, opening the door for mid-level manufacturers. By allowing contractors to control inventory and produce materials on demand, this innovation provided a significant competitive edge.  

The 2000s saw the introduction of semi-automated systems, streamlining tasks like job tracking and material handling. By 2015, fully automated coil warehouses had revolutionized the industry, incorporating advanced features such as automatic coil selection, slitting knife adjustments and barcode labeling. These developments significantly reduced material waste and improved efficiency. 

Benefits of in-house coil processing 

Transitioning to in-house coil processing presents challenges such as space requirements, training needs and initial investment. However, the benefits far outweigh the drawbacks: 

• Cost savings: In-house processing can reduce material costs by 20-30%. 
• Operational flexibility: Contractors can manufacture materials on demand, minimizing dependency on suppliers. 
• Improved jobsite control: Producing materials to exact specifications enhances project efficiency. 
• Revenue opportunities: Contractors can diversify their business by supplying processed materials to others. 
• Inventory management: A single master coil can be used for multiple projects, optimizing storage and material handling. 

The future of coil processing 

Automation continues to evolve, with hybrid systems making advanced processing more accessible. Contractors leveraging these technologies can optimize and take control of their coil processing, positioning themselves for long-term success in the metal industry. 

For a deeper dive into coil processing advancements and how they can impact your business, check out the full article in Metal Construction News or watch this RCS Lunch & Learn.