03/06/2026
Adding an Automated Part Stacking and Counting System to a Roll Forming Line
A manufacturer of steel framing recently rebuilt one of its production lines to run at a much faster operating speed. It quickly became clear that a single operator could no longer keep up with stacking the pieces, counting how many went into each box, and stapling the carton shut at the new machine speed the way it had been handled at the slower rate. The operator now had to halt the line repeatedly just to verify the number of parts going into each carton. These unplanned, periodic stoppages were removed once the automated counting and stacking system was installed.
With the line running faster and the new automated material handling taking over the counting and stacking, a single operator could focus solely on loading and sealing the parts into cartons.
Output jumped by 40 percent — far more than the increase in machine speed would have delivered on its own.
The reason production rose beyond expectations is that the operator no longer had to pause the line whenever the "count" was in question. Packing bundles of 20, 25, or 30 pieces became the operator's only task, with no need to STOP and verify the count.
There was a safety benefit as well: the constant, repetitive hand motion required to handle each individual part was eliminated, reducing the risk of carpal tunnel injury, and the operator was also moved a safe distance away from the machine's exit point.
Investing in the counting and stacking material handling setup delivered noticeably higher continuous output, more ergonomic and safer work for the employee, and a solid return on every front
Wilson Mai
Sales Executive
[email protected]
