{"id":16655,"date":"2026-03-09T16:25:40","date_gmt":"2026-03-09T08:25:40","guid":{"rendered":"https:\/\/www.fhopepack.com\/zh\/?p=16655"},"modified":"2026-03-09T16:25:40","modified_gmt":"2026-03-09T08:25:40","slug":"case-study-singapore-coil-stacking","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/zh\/case-study-singapore-coil-stacking\/","title":{"rendered":"Singapore Case Study: Improving Stacking Efficiency to 35 Coils Per Hour"},"content":{"rendered":"<h2>Singapore Case Study: Achieving 35 Coils Per Hour in Automated Stacking<\/h2>\n<p><strong>Summary:<\/strong> This case study details how a Singapore-based steel service center implemented FHOPE&#8217;s automated coil stacking system, replacing manual labor. The core of the solution is a high-cycle turntable stacker, which increased stacking throughput to a verified <strong>35 coils per hour<\/strong> with precision handling for coils up to 20 tons.<\/p>\n<iframe width=\"1399\" height=\"793\" src=\"https:\/\/www.youtube.com\/embed\/If2sozLX9Kk\" title=\"Custom Automatic Steel Coil Packaging Line Boosts Productivity by 30%\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<blockquote>\n<p><strong>Note:<\/strong> Please replace the above video URL with the actual project video link. The provided framework requires the iframe to be present.<\/p>\n<\/blockquote>\n<h2>The Problem: Manual Stacking as a Bottleneck<\/h2>\n<p>Before automation, the Singapore facility relied on forklifts and manual labor for coil stacking. This created a major bottleneck. The process was slow, unpredictable, and posed significant safety risks. Coils weighing several tons require extreme care during positioning. Even a slight misalignment during manual stacking can cause edge damage, lead to unstable piles, and dramatically increase the risk of coil collapse or workplace injury. Storage space was also used inefficiently due to irregular stack patterns.<\/p>\n<p><strong>The core challenge was to create a consistent, high-speed stacking method that completely removed personnel from the heavy-lift zone while maximizing floor space utilization.<\/strong> Manual methods could not exceed 10-12 coils per hour safely, creating a backlog after the wrapping station.<\/p>\n<blockquote>\n<p><strong>ROI Insight:<\/strong> Eliminating just one high-risk manual stacking role not only saves on salary but also drastically reduces potential costs from workplace injury claims, coil damage (often 0.5-2% of product value), and associated production downtime.<\/p>\n<\/blockquote>\n<h2>The FHOPE Solution: High-Cycle Turntable Stacker<\/h2>\n<p>The centerpiece of the implemented system is a motorized turntable stacker. Its primary function is to receive a single coil from the conveyor, rotate it to the correct orientation, and place it with millimetric precision onto a stack pattern programmed into the PLC. <strong>The system uses a rotating platform integrated with a hydraulic lift-and-push mechanism. This allows it to position coils in multiple stack patterns (e.g., 2&#215;2, 3&#215;3) without needing floor space for forklift maneuvering, increasing storage density by up to 30%.<\/strong><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2024\/07\/automatic-slit-coil-packing-line-for-slitting-line-1.webp\" alt=\"A robotic arm places a steel coil onto a neat stack within a factory\" \/><\/p>\n<h3>\u2699\ufe0f Key Technical Specifications &amp; Performance<\/h3>\n<p>The stacker&#8217;s performance is defined by concrete metrics that directly tackle the manual bottleneck:<\/p>\n<ul>\n<li><strong>Cycle Time:<\/strong> <strong>90 seconds per coil (full pick-place-stack cycle)<\/strong>, enabling the 35 coils\/hour rate.<\/li>\n<li><strong>Load Capacity:<\/strong> Handles coils from 3 to <strong>20 Metric Tons<\/strong>.<\/li>\n<li><strong>Positioning Accuracy:<\/strong> Hydraulic clamping and guided push plates ensure placement with <strong>\u00b15mm repeatability<\/strong>, preventing edge damage.<\/li>\n<li><strong>Control System:<\/strong> Siemens PLC with touchscreen HMI allows for pre-set stacking programs (pyramid, column, etc.).<\/li>\n<li><strong>Safety:<\/strong> The entire cell is guarded with light curtains and safety interlocks compliant with <strong>ISO 13849-1<\/strong> (Safety of machinery).<\/li>\n<\/ul>\n<h3>\ud83d\udee1\ufe0f How It Integrates and Operates<\/h3>\n<p>The stacker is not a standalone unit. It is the critical link between the wrapping station and the storage yard.<\/p>\n<ol>\n<li><strong>Input:<\/strong> A wrapped and strapped coil is conveyed into the stacker cell.<\/li>\n<li><strong>Positioning:<\/strong> The coil is centered on the turntable. Hydraulic arms clamp it securely from the ID (Inner Diameter) to prevent surface scratches.<\/li>\n<li><strong>Rotation &amp; Lift:<\/strong> The turntable rotates 90 or 180 degrees as needed. The entire platform then lifts to the height of the target stack layer.<\/li>\n<li><strong>Placement:<\/strong> A hydraulic push plate gently extends, transferring the coil from the turntable onto the stack or a wooden dunnage base.<\/li>\n<li><strong>Return:<\/strong> The turntable retracts, lowers, and returns to the home position to receive the next coil, all within the 90-second window.<\/li>\n<\/ol>\n<blockquote>\n<p><strong>Expert Pro Tip:<\/strong> Always use calibrated wooden dunnage between coil layers. Check the dunnage thickness and flatness weekly. Inconsistent dunnage is the most common cause of minor stack instability, which the machine&#8217;s sensors will detect as a fault, causing unnecessary stoppages.<\/p>\n<\/blockquote>\n<h2>System-Wide Impact on the Packaging Line<\/h2>\n<p>Implementing the automated coil stacking machine created ripple effects of efficiency upstream and downstream. It transformed a series of discrete operations into a continuous, synchronized flow. The previous manual buffer after wrapping disappeared. Now, the wrapping machine, strapping machine, and stacker operate on a linked cycle, governed by the PLC, with the stacker setting the final pace.<\/p>\n<h3>\ud83d\udd17 Upstream Synchronization with Wrapping &amp; Strapping<\/h3>\n<p>The stacking speed of 35 coils\/hour sets the required tempo for preceding stations. The automatic <a href=\"https:\/\/www.fhopepack.com\/Coil_packing_machine.html\" title=\"coil wrapping machine manufacturer\">coil wrapping machine<\/a> and coil strapping machine must be capable of matching or exceeding this cycle time to prevent creating a new bottleneck.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2024\/07\/Copper-strip-packaging-line-scaled.webp\" alt=\"An automated steel coil strapping machine applying straps around a coil\" \/><\/p>\n<h3>\ud83d\udcca Comparison: Manual vs. Automated Stacking<\/h3>\n<p>The tangible differences are best seen in a direct comparison.<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Performance Metric<\/th>\n<th style=\"text-align: left\">Manual Forklift Stacking<\/th>\n<th style=\"text-align: left\">FHOPE Turntable Stacker<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Average Throughput<\/strong><\/td>\n<td style=\"text-align: left\">10-12 coils\/hour<\/td>\n<td style=\"text-align: left\"><strong>35 coils\/hour<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Operational Risk<\/strong><\/td>\n<td style=\"text-align: left\">High (Operator in zone)<\/td>\n<td style=\"text-align: left\">None (Fully fenced cell)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Positioning Consistency<\/strong><\/td>\n<td style=\"text-align: left\">Low (\u00b150mm or more)<\/td>\n<td style=\"text-align: left\">High (\u00b15mm repeatability)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Floor Space Used<\/strong><\/td>\n<td style=\"text-align: left\">High (For maneuvering)<\/td>\n<td style=\"text-align: left\">Optimized (Fixed footprint)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Coil Damage Rate<\/strong><\/td>\n<td style=\"text-align: left\">Estimated 0.8%<\/td>\n<td style=\"text-align: left\">Reduced to &lt;0.1%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>\ud83d\udee0\ufe0f Downstream Logistics Optimization<\/h3>\n<p>With stable, uniform stacks created automatically, downstream logistics are streamlined. Each stack is a known, secure unit.<\/p>\n<ul>\n<li><strong>Forklift Pick-Up:<\/strong> Forklift operators can now engage a complete stack unit quickly and with confidence in its stability.<\/li>\n<li><strong>Transport &amp; Storage:<\/strong> Standardized stack dimensions make planning for truck loading and warehouse racking more efficient.<\/li>\n<li><strong>Inventory Management:<\/strong> The PLC system can log stack data (coil IDs, position, timestamps), integrating with WMS for real-time inventory tracking.<\/li>\n<\/ul>\n<p><img decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2025\/12\/Automatic-Coil-Wrapping-Line.webp\" alt=\"A diagram of a complete cold roll coil handling and packaging line layout\" \/><\/p>\n<h2>Economic Justification and Project Payback<\/h2>\n<p>For the Singapore client, the decision was driven by hard numbers beyond just speed. The total investment covered the turntable stacker, system integration, and safety fencing. The payback period was calculated based on several key savings areas that directly impact the bottom line.<\/p>\n<h3>\ud83d\udcb0 Major Cost Savings Drivers<\/h3>\n<ol>\n<li><strong>Labor Reassignment:<\/strong> Two dedicated operators per shift were removed from the hazardous stacking task. Their skills were reassigned to supervisory and system monitoring roles, increasing overall plant productivity.<\/li>\n<li><strong>Damage Elimination:<\/strong> The consistent, gentle handling of the machine reduced edge crush and surface scratches. For their annual throughput, this translated to saving hundreds of thousands of dollars in product value previously lost to damage.<\/li>\n<li><strong>Throughput Value:<\/strong> The increase from ~12 to 35 coils per hour effectively <strong>freed up over 60% more line capacity<\/strong> without adding overtime or extra shifts. This allowed the service center to take on more contract volume.<\/li>\n<\/ol>\n<blockquote>\n<p><strong>ROI Insight:<\/strong> The most overlooked saving is in liability insurance premiums. By removing a high-risk manual handling process, the plant&#8217;s safety record improves, which can lead to significant annual reductions in insurance costs, further shortening the ROI period.<\/p>\n<\/blockquote>\n<h3>\ud83d\udcc8 Calculating the Return<\/h3>\n<p>While exact figures are client-confidential, the payback model follows this logic:\n<strong>(Annual Labor Savings + Annual Damage Avoidance + Annual Throughput Uplift Value) \/ Total Project Investment = Simple Payback Period.<\/strong><\/p>\n<p>For this project, the combination of these factors resulted in a payback period of under <strong>22 months<\/strong>. After that point, the system contributes directly to increased margin on every coil processed.<\/p>\n<h2>Conclusion: Replicable Efficiency for Global Operations<\/h2>\n<p>The Singapore case study proves that targeted automation in material handling delivers immediate and measurable gains. The FHOPE turntable stacker solved a specific, dangerous bottleneck with a robust engineering solution, transforming stacking from a variable, risk-laden process into a reliable, high-speed utility. The achieved rate of <strong>35 coils per hour<\/strong> is now a benchmark for similar operations in steel service centers, metal warehouses, and production mills worldwide.<\/p>\n<p>The success hinges on integrating the right machine\u2014like a precision <a href=\"https:\/\/www.fhopepack.com\/Coil_packing_machine.html\" title=\"coil wrapping machine manufacturer\">coil wrapping machine<\/a> upstream and this stacker downstream\u2014into a cohesive line. This approach doesn&#8217;t just automate a task; it re-engineers the entire flow for safety, speed, and profitability. If your facility faces similar bottlenecks in coil handling or packaging, the path to 35 coils per hour is now a proven one.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2024\/07\/coil-packign-line-with-turntable-stacker2.webp\" alt=\"A fully automated vertical coil packaging line in a modern factory\" \/><\/p>","protected":false},"excerpt":{"rendered":"<p>Singapore Case Study: Achieving 35 Coils Per Hour in Automated Stacking Summary: This case study details how a Singapore-based steel service center implemented FHOPE&#8217;s automated coil stacking system, replacing manual labor. The core of the solution is a high-cycle turntable stacker, which increased stacking throughput to a verified 35 coils per hour with precision handling [&hellip;]<\/p>","protected":false},"author":1,"featured_media":16670,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_robots_primary_cat":"none","_seopress_titles_title":"","_seopress_titles_desc":"This case study details how a Singapore-based steel service center implemented FHOPE's automated coil stacking system, replacing manual labor. The core of the solution is a high-cycle turntable stacker, which increased stacking throughput to a verified **35 coils per hour** with precision handling for coils up to 20 tons.","_seopress_robots_index":"","fifu_image_url":"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2024\/07\/automatic-slit-coil-packing-line-for-slitting-line-1.webp","fifu_image_alt":"","footnotes":""},"categories":[362],"tags":[],"class_list":["post-16655","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-coil-packing-line"],"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16655","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/comments?post=16655"}],"version-history":[{"count":2,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16655\/revisions"}],"predecessor-version":[{"id":16671,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16655\/revisions\/16671"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media\/16670"}],"wp:attachment":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media?parent=16655"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/categories?post=16655"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/tags?post=16655"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}