Recently, KINGREAL Roll Former successfully completed the manufacturing and internal testing of a custom-developed automatic coil to pack system for drywall profile for a major Russian client.
To address the client's pain points regarding low efficiency and high labor costs in the post-processing stage (strapping, packaging, and stacking), KINGREAL Roll Former provided a precise automation solution.
This coil to pack system for profile significantly reduces labor expenses and lays a solid foundation for the exponential growth of the client's production output.
Project Background and Core Pain Points
The Russian client is a leading supplier of drywall profiles in the local construction industry, operating multiple high-output drywall profile machines. With the recent rapid expansion of Russia's infrastructure and prefabricated construction markets, the client has experienced a surge in orders and rising daily production requirements.
However, the client faced a critical production imbalance:
A mismatch between production speed and packaging efficiency: While the drywall profile machines operated at industry-leading speeds, the downstream process still relied heavily on manual labor for counting, aligning, strapping, and stacking. Manual processing speeds could not keep pace with machine output, forcing the drywall profiles to frequently slow down and creating a severe production bottleneck.
Inconsistent packaging quality: Manual strapping often resulted in uneven tension and untidy stacking. During long-distance transport, loose bundles were prone to profile deformation or surface scratches, directly compromising the quality of the delivered product.
High labor costs and recruitment challenges: Repetitive, heavy manual handling led to high staff turnover and persistently high management costs.
Consequently, the client urgently required a coil to pack system for profile capable of seamlessly matching their high production rates, thereby freeing up manpower and ensuring industrial-standard packaging quality.
Customized Coil to Pack System for Drywall Profile Solution Design
In the early stages of the project, the KINGREAL Roll Former team engaged in multiple rounds of in-depth technical consultation with the Russian client.
We conducted a detailed analysis of the client's average daily output, intended packaging materials, bundle quantities, profile specifications and dimensions, and surface protection requirements.
Precision Customized Parameters
KINGREAL Roll Former implemented a targeted modular design for the coil to pack system for profile to meet the specific requirements of Russian clients:
Operating Speed: The coil to pack system for drywall profile achieves a maximum speed of 70 m/min, perfectly matching mainstream high-speed drywall profile machines.
Bundling Logic: Supports bundle configurations of 8–16 pieces. For instance, aligning with Russian market preferences, a "3-wide, 2-high, double-row" pattern (3 x 2 x 2 = 12 pieces) was designed to ensure structural stability and facilitate forklift loading and unloading.
Surface Protection Design
Given that the profiles are primarily made of galvanized steel, KINGREAL Roll Former installed specially designed soft-coated buffer heads at all contact points and actuating components to prevent surface scratches during high-speed gripping and stacking.
This design effectively eliminates direct metal-on-metal impact.
Flexible Integration Capabilities
The coil to pack system for drywall profile offers exceptional operational flexibility:
Standalone Mode: Clients can operate it as an independent unit; profiles are manually fed into the inlet, and the machine automatically completes the subsequent processes.
Fully Automated In-line Mode: The coil to pack system for profile can be seamlessly integrated at the discharge end of the client's existing drywall profile machine, enabling a fully automated workflow from steel coil to finished profile bundle.
Rigorous Commissioning and FAT Acceptance
Following manufacturing, KINGREAL Roll Former engineers conducted simulated production trials at the factory. By replicating the Russian client's actual operating conditions, we verified the coil to pack system for profile's functionality across the entire process.
1. Automated Process Demonstration
During acceptance testing, the coil to pack system for drywall profile demonstrated excellent motion coordination: after entering the infeed section, the profiles pass sequentially through the interlocking section, stacking section, wrapping section, and pulling section, finally reaching the palletizing stage. The entire process operates seamlessly and precisely without manual intervention.
2. Fine-tuning of Parameters
To ensure consistent performance when handling profiles of various specifications, technical staff repeatedly adjusted the tension parameters of the servo system.
Whether handling thinner partition wall studs or thicker load-bearing profiles, the strapping tension remains consistent, ensuring the bundles do not loosen or shift during lifting and transport.
The Russian client participated in the coil to pack system for profile inspection via video link. Their feedback was highly positive: "The surface of the strapped profiles is perfectly smooth-free of any scratches-and the bundling is incredibly tight. The level of automation far exceeded our expectations."
Commitment to Ongoing Service
KINGREAL Roll Former recognizes the importance of maintenance for industrial equipment in cross-border operations and has established a comprehensive after-sales support system:
End-to-end logistics tracking
Providing real-time updates on the shipment process from the Chinese port to the client's facility.
Diverse technical support
For installations in Russia, KINGREAL Roll Former offers a dual approach combining real-time online video guidance with on-site engineering support, ensuring the coil to pack system for drywall profile is commissioned and operational in the shortest possible time.
Full lifecycle assurance
Including a reliable supply of spare parts, reminders for scheduled remote inspections, and options for future technical upgrades, giving clients complete peace of mind.
To date, KINGREAL Roll Former coil to pack system for profile have been deployed in numerous countries and regions, including Belgium, Algeria, Kazakhstan, Aruba, and Mexico.
Moving forward, we will continue to increase our investment in Russia and neighboring markets, focusing deeply on regional needs and empowering the industrialization of the construction sector across more regions with reliable, intelligent machine.