{"id":15317,"date":"2026-09-11T09:16:04","date_gmt":"2026-09-11T09:16:04","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=15317"},"modified":"2026-10-29T18:04:43","modified_gmt":"2026-10-29T18:04:43","slug":"4-core-packaging-kpis-how-steel-coil-strapping-wrapping-lines-lower-tco-and-cut-transit-damage-by-90","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/4-core-packaging-kpis-how-steel-coil-strapping-wrapping-lines-lower-tco-and-cut-transit-damage-by-90\/","title":{"rendered":"Steel Coil Strapping, Labelling and Stacking Line: Four Performance KPIs We Track"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nSlit coils pass a top-face head station, a gantry stacker builds them onto a pallet, and a second line shows an overhead-arm station run from its own HMI.\nWe judge a line like this on four numbers you can measure yourself: seconds per coil at the slowest station, first-pass label reads, stack quality and film use per coil. Each one has a simple formula, shown below.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"1053\" height=\"592\" src=\"https:\/\/www.youtube.com\/embed\/aihySbLbCN4\" title=\"Automatic Steel Coil Strapping, Labeling and Stacking Line\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#video\">What the machine does<\/a><\/li>\n<li><a href=\"#kpi-cycle\">KPI 1: seconds per coil at the slowest station<\/a><\/li>\n<li><a href=\"#kpi-label\">KPI 2: first-pass label reads<\/a><\/li>\n<li><a href=\"#kpi-stack\">KPI 3: stack quality at the gantry stacker<\/a><\/li>\n<li><a href=\"#kpi-film\">KPI 4: film use per coil<\/a><\/li>\n<li><a href=\"#selection-checklist\">Selection checklist for a coil labelling and stacking line<\/a><\/li>\n<li><a href=\"#safety\">Controls and safety<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step\">Next step<\/a><\/li>\n<li><a href=\"#related-reading\">Related reading<\/a><\/li>\n<li><a href=\"#sources\">Sources<\/a><\/li>\n<\/ul>\n<h2 id=\"video\">What the machine does<\/h2>\n<p>The line runs three stations in sequence:<\/p>\n<table>\n<thead>\n<tr>\n<th>Station<\/th>\n<th>What happens<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Top-face head station<\/td>\n<td>Coils lie eye-to-sky on the roller table; each one stops under a portal and a strapping head lowers onto the top face<\/td>\n<\/tr>\n<tr>\n<td>Gantry stacker<\/td>\n<td>A gantry gripper picks the coils and lowers them in a stack onto a pallet on the outfeed conveyor<\/td>\n<\/tr>\n<tr>\n<td>Overhead-arm station<\/td>\n<td>A second line, run from its own HMI column, works over a coil on the roller conveyor<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Coils move between stations on rollers or in the gripper, without manual handling.<\/p>\n<p>The four KPIs below are how you check a line like this on your own floor.<\/p>\n<h2 id=\"kpi-cycle\">KPI 1: seconds per coil at the slowest station<\/h2>\n<p>A coil line runs at the pace of its slowest station. Labelling, stacking and wrapping each have their own cycle; the longest one sets output.<\/p>\n<p>Coils per hour = 3600 \u00f7 seconds per coil at the slowest station.<\/p>\n<p>Measure each station separately with the line running real coils, not a demo. Then compare the result with your slitter output. If the slitter makes coils faster than the slowest packing station can take them, coils queue and the line operator starts making manual decisions.<\/p>\n<p>On our proposals we list a cycle per station, so you can see which one is the limit. A buffer conveyor ahead of the slowest station absorbs short stops but does not raise average output.<\/p>\n<h2 id=\"kpi-label\">KPI 2: first-pass label reads<\/h2>\n<p>A label is only useful if the warehouse scanner reads it the first time.<\/p>\n<p>First-pass read rate = labels read at first scan \u00f7 labels applied.<\/p>\n<p>Three engineering variables govern label legibility:<\/p>\n<ul>\n<li><strong>Label position.<\/strong> A fixed label head puts the label in the same place on every coil, so a scanner or forklift driver finds it.<\/li>\n<li><strong>Label data.<\/strong> Our coil lines can take coil data from ERP or MES, so the label matches the coil record without retyping.<\/li>\n<li><strong>Surface.<\/strong> The head needs a clean, flat area on the face. We place the labelling station where the coil face is still accessible, before film covers it, or we label the film, depending on your logistics.<\/li>\n<\/ul>\n<p>Track rejected or re-printed labels per shift. A rising count points to position drift or a print-head issue long before customers complain.<\/p>\n<h2 id=\"kpi-stack\">KPI 3: stack quality at the gantry stacker<\/h2>\n<p>The gantry stacker builds a stack of coils on a pallet. Two checks tell you whether stacking is right:<\/p>\n<ul>\n<li><strong>Centring error:<\/strong> how far each coil sits off the stack axis. An offset stack leans and loads one side of the pallet.<\/li>\n<li><strong>Re-stack count:<\/strong> stacks an operator had to straighten or rebuild by hand, per shift.<\/li>\n<\/ul>\n<p>Stacks per hour = coils per hour \u00f7 coils per stack.<\/p>\n<p>Our coil line quote form allows stacks of up to 6 coils. Your working height comes from coil weight, coil width, the pallet and forklift capacity. We set it with you at layout stage.<\/p>\n<h2 id=\"kpi-film\">KPI 4: film use per coil<\/h2>\n<p>Film is a running cost, so measure it per coil, not per month.<\/p>\n<p>Film mass per coil (g) = film length used (m) \u00d7 film width (mm) \u00d7 thickness (\u00b5m) \u00d7 density (g\/cm\u00b3) \u00f7 1000.<\/p>\n<p>Keep the units exactly as written and the factor of 1000 does the conversion.<\/p>\n<p>Weigh a full film roll, wrap a known number of coils, weigh the roll again, and divide. Do this for each coil size you run. If film use per coil drifts up with no change in coil size, check the tension and overlap settings first.<\/p>\n<p>Our coil line programs store tension and overlap per coil specification, so a size change does not depend on the operator re-tuning by hand.<\/p>\n<h2 id=\"selection-checklist\">Selection checklist for a coil labelling and stacking line<\/h2>\n<ul>\n<li>Coil OD, ID, width and weight range, and the heaviest coil on the order.<\/li>\n<li>Label content, label position (face or film) and the data source: ERP, MES or manual.<\/li>\n<li>Strapping before stacking: PET or steel strap, and how many straps (see our <a href=\"https:\/\/www.fhopepack.com\/videos\/in-depth-engineering-evaluation-optimizing-tilting-dynamics-strapping-tension-and-film-stretch-ratios-for-ultra-thin-slit-coils\/\">slit coil strapping and wrapping line<\/a>).<\/li>\n<li>Wrap material: stretch film, paper or woven, and the overlap you specify.<\/li>\n<li>Stack height, pallet type and forklift access to the outfeed.<\/li>\n<li>Final packaging orientation: eye-to-sky (vertical axis) or eye-to-wall (horizontal axis).<\/li>\n<li>Target coils per hour from your slitter, and the station you expect to limit it.<\/li>\n<\/ul>\n<h2 id=\"safety\">Controls and safety<\/h2>\n<p>The standards that apply depend on the destination market. For CE markets, ISO 12100 sets the risk-assessment method and EN 415-10 covers general requirements for packaging machines, which fixes guarding and the emergency-stop arrangement.<\/p>\n<p>The head stations, the gantry gripper and the overhead arm are the moving hazards. The stacker zone is fenced; label and film changes are done with the station stopped.<\/p>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p>Q: Which KPI should we track first on a new coil packing line?\nA: Seconds per coil at the slowest station. It sets coils per hour (3600 \u00f7 that time) and tells you where a buffer or a second machine would pay back.<\/p>\n<p>Q: How do we measure first-pass label reads?\nA: Calculate the ratio of valid initial barcode scans against total labels applied over a full production shift. Manual keyboard entries, re-printed labels, and non-reads count as failed passes.<\/p>\n<p>Q: Can labels be applied after wrapping?\nA: Yes. The system can be programmed to apply shipping labels directly to the bare metal face prior to outer wrapping, or onto the exterior film layer after orbital wrapping, depending on warehouse scanning protocols.<\/p>\n<p>Q: What should we inspect first if film use per coil goes up?\nA: If film use rises with no change in coil size, check the tension and overlap settings in the coil program first. Measure it by weighing the roll before and after a counted batch.<\/p>\n<p>Q: How high can the gantry stack coils?\nA: Our quote form takes up to 6 coils per stack. The working height depends on coil weight, width, pallet and forklift.<\/p>\n<h2 id=\"next-step\">Next step<\/h2>\n<p>Line integration and hardware dimensioning follow three systematic steps:<\/p>\n<ol>\n<li><strong>Submit your layout drawing<\/strong> with the coil OD, ID, width, weight, label content and output target, to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Receive an engineering proposal within 48 hours<\/strong>, complete with station cycle time models to verify line balance against your slitter output.<\/li>\n<li><strong>Book a site survey<\/strong> so we confirm the slitter exit, the line direction and forklift access to the stacks.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-copper-strip-coil-packing-line-with-labeling-wrapping-stacking-system\/\">Automatic Copper Strip Coil Packing Line with Labeling, Wrapping and Stacking<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/coil-wrapping-machine-with-tapping-and-barcode-printer\/\">Coil Wrapping Machine with Taping and Barcode Label Printer<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automated-slit-coil-packing-line-for-service-center-boost-your-productivity\/\">Slit Coil Packing Line for Service Centers<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/continuous-downtime-inconsistent-tension-or-manual-bottlenecks-what-is-the-primary-failure-point-in-your-stainless-steel-coil-packaging-line\/\">Stainless Steel Coil Packaging Line: Tilting, Eye-Through Wrapping, Labelling and Stacking<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-Coil-Packing-Line\/\">Automatic Coil Packing Line<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>Line family, ERP\/MES labelling, programs, stacking height on the quote form, strapping and wrap options: <a href=\"https:\/\/www.fhopepack.com\/Automatic-Coil-Packing-Line\/\">Automatic Coil Packing Line<\/a><\/li>\n<li>Machinery design and risk standards: ISO 12100:2010; <a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014<\/a><\/li>\n<li>Standard technical proposal protocol: Engineering review and proposal submission within 48 hours<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-29<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary Slit coils pass a top-face head station, a gantry stacker builds them onto a pallet, and a second line shows an overhead-arm station run from its own HMI. We judge a line like [&hellip;]<\/p>","protected":false},"author":4,"featured_media":15321,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Steel Coil Labelling & Stacking: 4 Line KPIs","_seopress_titles_desc":"Our steel coil line handles, labels and gantry-stacks slit coils. 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