Above: One part of the line performs circumferential strapping.
January, 2026- A major steel service center is relying on Biele with the installation of a highly automated packaging line for slit coils. This system, according to Biele, is a forward-looking concept that is currently in startup phase.
Similar to a previously delivered line to another European customer by KBD Automation, the German company belonging to Spain’s Biele Group, the new line enhances capabilities, while all processes are designed to be continuously automated and energy efficient. Because of the high degree of automation, operation in standard mode is possible almost without operating personnel. This not only significantly increases the productivity and efficiency of the packaging process, but also ensures the quality and integrity of sensitive materials.
TAILOR MADE
Biele Group provides automation solutions, packaging systems and material flow optimization for metal service centers. The company places special focus on customer specific, tailor-made solutions that are precisely aligned to the requirements and conditions of each production site.
A current project realized for a major steel service center in Europe demonstrates the company’s holistic approach. The aim was to fully automate the packaging of slit coils from takeover at the end of the slitting line to provisioning for shipment. Through this integrated solution, the slit-coil packages can be transported to the loading ramp within minutes after slitting, ready for shipment.
This enables a waste-free, continuous material flow in the plant, which is precisely aligned with production planning.
Another part of the line performs radial multi strapping.
PROCESS INTEGRATION
The installed packaging line integrates all essential process steps and units in a compact, continuous structure. These include:
• Circumferential strapping
• Slit coil marking
• Separation and tilting
• Radial strapping
• Pallet feeding
• Stacking on pallets with intermediate wood
• Securing the stack to the pallet
• Wrapping the package with stretch film and film top sheet
• Transfer of secured packages to plant logistics (“eye to sky” or “eye to wall”)
• Net and gross weighing, as well as labeling of the package
All drives in the line are designed electromechanically, reducing the use of hydraulic systems to an absolute minimum. This leads to lower maintenance requirements, higher energy efficiency and a significant improvement in process stability.
Biele Group built a slit coil packaging line for a European steel service center.
The system relies on IO-Link sensors at all relevant points, enabling digital and interference- free transmission of process and diagnostic data between the field level and the control system. Parameters can be centrally managed and automatically restored after sensor replacement, simplifying commissioning and maintenance significantly. The result is a networked sensor structure that enables precise process monitoring and databased optimization.
HEAVY-DUTY TURNSTILES
The packaging line begins with three high-performance turnstiles, each with a load capacity of up to 35 tonnes per arm. The first turnstile serves as the interface between the slitting line and the packaging line. It is equipped with an active hold-down device that takes over the unsecured slit-coil package from the coil car, fixes it and transfers it into the circumferential strapping station.
Rotation and positioning are carried out by electric gear motors. Only the locking mechanism and the hold-down pressing device are executed by compact hydraulic cylinders.
CIRCUMFERENTIAL STRAPPING
The circumferential strapping system is a combined unit consisting of a strapping machine and a freely rotatable hold-down device mounted on the turnstile. The hold down can be positioned electromechanically above any turnstile arm.
The system takes over the unsecured set of slit coils from the slitting line’s coil car. A so called piano keyboard on the hold-down fixes the package before it rotates for strapping.
For precise strapping of the individual slit coils on the turnstile arm, an initial measurement of the slit-coil package is carried out. This enables correct positioning of the straps regardless of the distance between coils. Based on these data, the strapping equipment can be placed exactly at the correct position on each slit coil—and for wider coils at multiple positions—using servo motors and positioning technology. The active hold-down allows the band channel to be fully closed and the straps to be placed around the slits without interference.
The precise manufacturing of the machine and its high-tech components enables secure packaging of narrow slit coils by the exact interplay of mechanics, controls and sensor technology.
INTEGRATED PRINTER
During the strapping process, the individual slit coils are labeled or printed directly on the strap. Marking, such as a QR code or barcode, is performed automatically based on production data from the ERP system transmitted to the printer. This networked and fully integrated solution eliminates material mixups and ensures secure material tracking throughout all process steps.
UNINTERRUPTED MATERIAL FLOW
After circumferential strapping, the secured package is transferred to the second turnstile by an electric coil car. This electric setup reduces energy requirements and avoids disadvantages of hydraulic systems (leakage, oil temperature, maintenance).
From the second turnstile, the material can either be diverted via a separate discharge line onto a third buffer turnstile by means of an additional coil car, or continue along the main line for complete packaging. This discharge line is an internal plant-specific feature installed for large slit coils and for internal logistics purposes.
In a standard operation, the package reaches the tilting table, which separates the slit coils from the second turnstile and tilts them into a horizontal position. The table is designed to handle coils up to 6 tonnes, while enabling precise separation of particularly narrow coils. If the slit coils have become hooked together, this is detected at the separation phase, using sensors and algorithms. A programmed sequence of movements resolves the interlocking so that the process can continue without disruption.
The lifting motion during separation is carried out hydraulically via a high-precision “finger,” while the tilting motion is executed efficiently via gear servo motors. The tilting table is designed without rollers to avoid any lateral movement or surface damage to the rings.
MAGNETIC MOVEMENT
Above the tilting table is a gantry system with two magnetic grippers spanning three stations: the tilting table, the radial strapping table and the stacking wagon. The grippers use electro-permanent magnets, enabling safe and energy-efficient handling of slit coils weighing up to 6 tonnes.
The gantry features two independent manipulators that travel on rails, driven electromechanically along the Z axis. This vertical motion is powered via a highperformance spindle, ensuring low-maintenance operation. An automatic lubrication system is installed to ensure long service life and easy maintenance.
The two manipulators ensure short cycle times while providing redundancy: in the event of failure, the system can continue operating with one manipulator without requiring a shutdown. The gantry is equipped with parking positions on both sides that allow one manipulator to move aside and production to continue, a key factor in plant availability.
RADIAL MULTI-STRAPPING
A radial strapping table is equipped with four strapping heads arranged in a 90-degree pattern. These enable simultaneous fourfold radial strapping, reducing the process time for this step.
Intelligent functions in each strapping head ensure that strap tensioning is carried out gently, meaning that even at sharp edges, the strap is securely tightened with the set force. An electronic weighing system is integrated into the table. The design of the strapping table allows ergonomic strap loading during setup. Even in service cases, fast access to the strapping heads is ensured, and replacement of strapping devices can be carried out extremely quickly.
Behind each strapping head is a jumbo pallet band dispenser, which reduces loading intervals. The slit-coil packages can be transported to the loading ramp within minutes after slitting, ready for shipment.
CAROUSEL STATIONS
Once the slit coils are fully secured circumferentially by fourfold radial strapping, they are stacked on pallets according to order. This task is fully automated by the packaging line.
Order-specific stacking takes place on independently moving stacking wagons arranged in a carousel system. Pallets can be placed on empty wagons in parallel to the main process, and the gantry manipulator always travels the same shortest path when stacking the slit coils.
FLEXIBLE PALLET FEED
The stacking wagons are equipped with a positioning system that exact stacking occurs on one side, while the position of the slit-coil packages and related components such as pallet and intermediate wood is always precisely known by the control system.
Pallets are supplied via a very flexible pallet magazine. Pallet stacks are supplied by a forklift under a gantry. The system is designed for different pallet sizes. The flexibility of the system lies in the ability to choose pallet sizes according to order control.
Intermediate wood spacers are automatically inserted by a rotary magazine with 30 compartments and an associated column manipulator. Similar to the pallet magazine, the compartments can be filled flexibly. They can hold intermediate wood of different lengths; only the maximum length is fixed during design. A column gripper picks up three intermediate wood pieces in a 120-degree star pattern and places them on the respective stack, on the top slit coil. The stacking wagon moves on the carousel between stacking and intermediate-wood stations until the order is fully stacked.
Stacking and later transport of the packages over roller conveyors always occur on pallets. This ensures that neither the coils nor the coil bundles come into contact with rollers at any time, eliminating any lateral movement that could damage edges or coils.
Slit coils are laid down on a carousel for additional packaging.
WRAPPING
After stacking is completed, the slit-coil packages are transferred from the carousel into the output area. Here, the package is first strapped to the pallet to create a transport-secure unit.
The strapping machine used for this is equipped with a variable lance system that enables flexible strapping in different patterns. The combination of turntable and strapping lances enables flexible selection of the securing pattern. The stack can be secured either with or without a pallet. This increases the degree of automation, allowing the packaging line to fully process even custom requests in a shipment-ready manner.
The machine installed at the steel service center was initially equipped with one strapping head, but preparations for a second head have already been made. If higher productivity at the line’s output is required, the system can quickly be expanded.
Once the slit-coil package is fully secured, a wrapper applies stretch film and a film top sheet that can cover the package completely. Depending on customer requirements, the system can choose between basic dust protection and robust overseas packaging.
Before the package leaves the line completely, it is weighed again. This is followed by transfer over a roller-chain crossover onto heavy-duty transport chains that deliver the package to logistics buffer stations. These stations are designed for simultaneous unloading of multiple positions.
To ensure damage-free removal of packages weighing up to 10 tonnes, pneumatic lifting devices take the packages off the chains so that forklift tines cannot damage the chains.
The buffer positions naturally also allow crane removal, either through the coil eye with an inner gripper, or laterally via pallets. It is also possible to integrate a pack stacker, so several packages can be stacked in the same buffer station. If the slit-coil packages exit the line in “eye to wall” orientation, a tilting unit is installed at the line end. Its electromechanical design allows fast and efficient tilting. Removal can be performed by forklift or C-hook.
SOFTWARE INTEGRATION
The new Biele line is integrated with the customer’s ERP and includes two modules for Live Overview and Production Controller. The Live Overview allows for a user-friendly interaction for easy access to the Line Status overview and key performance indicators, as well as access to alarms monitoring. The Production Controller offers centralized management. It takes into account the entire workflow, from recipe generation to production tracking until the coils are finally packed and properly labeled for shipment.
Biele Group believes it has installed one of the most advanced slit-coil packaging systems in the Europe market. Fully automated material flow, the consistent use of electromechanical drives, and integration of a holistic digitalization concept including unique slit-coil labeling create a greater level of efficiency, process reliability and data access. The result is short throughput times, minimized downtime, high process reliability and sustainably reduced operating costs. Biele’s modular system design enables easy scalability, both in terms of capacity and future requirements for traceability and data integration.
Biele Group, 706/537-2336, biele.com
