Every coil counts: Material Flow How® for wire rod
Pesmel’s unique Material Flow How® concept for wire rod producers is a logistics solution that goes far beyond traditional storage and warehousing. It turns intermediate storage facilities into highly-automated distribution centers that can improve throughput times and the efficiency, accuracy and quality of material handling.
The wide range of end uses for wire rods, which require accuracy and precision also set high quality requirements on the material itself. Pesmel’s solution for the packing, storage, and logistics for wire rod coils also minimizes the risk of mechanical damage and corrosion caused by moisture during storage and transportation. Pesmel wants to ensure that when the customer’s coils reach their final destination, that the quality of each one is as high as when it rolled off the production line.
A complete solution
The Material Flow How® concept covers the entire automated journey from receiving coils for packing and storage to delivering them for loading and transportation. The intelligent automation software behind the solution ensures the ease, accuracy, and efficiency of the entire process. The customer always knows the status and location of every single coil at all times, from the moment they are first delivered from production into the Pesmel carriage that takes them onto packing, or directly into storage depending on the customer’s needs.
Throughput time is the key to efficiency
Dealing with continuously growing production volumes and heavy products, logistics solutions need to be both agile and robust. The average wire rod line can produce up to 60 coils/hour, with each coil weighing 2-3 tons. Efficient and well-organized logistics can ensure smooth throughput with no bottlenecks. The intelligent Pesmel solution does not just store coils in the unique and space-saving vertical deep lane storage, but it has the ability to pre-sort outgoing orders for easy pickup well in advance. With an output capacity of 90 coils/hour and smart automated pre-sorting, the Pesmel solution can help reduce the turnaround time for a truck picking up a scheduled load to about 10-15 minutes in total. In a world where time is money, these types of improvements in efficiency are extremely valuable.
Pesmel’s TransRoll™ solution allows for coils to be stored up to a height of 30 meters in storage lanes that can hold up to ten coils each, depending on their dimensions. This means that a greater storage capacity can be achieved with a much smaller footprint than in traditional storage solutions or a typical storage yard. Stacker cranes can run between racks and pick up coils from either side. All Pesmel cranes and carriages are designed to handle multiple coils at a time to ensure maximum efficiency and throughput. The intelligent Warehouse Management System (WMS), the brains behind the entire operation, always knows exactly which coil is where. The order pickup process is guaranteed to be both fast and accurate.
Packing that protects product quality
For many wire rod applications, pristine quality is a high priority. Avoiding dings, dents, and scratches during storage and transportation can often be a matter of great importance. Many coils are stored and shipped without packing, in which case they can easily bypass the packing process and be moved into the high-bay storage. Pesmel’s automated packing line treats the coils requiring protective packing with the utmost care and efficiency. Before each coil is packed, it passes through a measurement station where lasers are used to measure and check each coil’s dimensions and check that there are no sharp coil ends protruding into the eye of the coil where they might cause tears during Through-Eye Wrapping (TEW) and result in unscheduled maintenance shutdowns and bottlenecks. The measurements also help optimize the use of packing materials and minimize waste in packing. This is a matter of both optimizing costs and minimizing the environmental impact of process waste.
Dealing with continuously growing production volumes and heavy products, logistics solutions need to be both agile and robust.
Each packing line is built based on the customer’s needs and specifications. Typically, wire rod coils are wrapped using Pesmel’s patented Through-Eye Wrapping Machine in two layers; first with a durable fabric layer, followed by a film wrapper, which provides a good seal and barrier from both mechanical damage during handling as well as moisture during storage and transportation. The wrapping process may also include extra wrapping and protection over the outside or ends of coils depending on the wire rod material’s specific attributes and transportation modes. Each coil is labelled using Pesmel’s automated labelling solution before storage. Restocking the label machine and the packing line once or twice per shift is the only manual operation throughout the entire packing, storage, and sorting process.
Each Pesmel Flow How® solution is designed and built to match the customer’s needs using proven technologies and components. A combination of high-quality hardware and intelligent software is the basis for each automated logistics solution. The entire journey and process between production and transportation can be automated to ensure high-quality material packing and handling, optimized use of storage space, and highly efficient material flows. Each Pesmel delivery is supported by comprehensive expert services, ensuring that assistance is always at hand. Experts provide extensive training for operators and on-site support during commissioning. Pesmel also offers its 24/7 Helpdesk service to each customer thereafter. As a company, Pesmel is committed to quality in terms of both solutions and services. They want to be the preferred intelligent logistics partner for the wire rod industry.
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