Coil is a type of conductor wire, such as copper, in a form that is cylindrical. It is wrapped around an iron core which creates an inductor or electromagnet that stores magnetic energy. Companies that focus on coil processing solutions cater to various metal-working industries around the world since they are aware that one size does not fit all. In process applications, it is the energy transfer efficiency that is the most important performance factor for coils.
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Industrial coils work great in industries such as grain processing, process drying, generating food processing, paper/ paper pulp, and chemical/ petrochemical, among many others.
Since there is a wide variety of applications and processing for coils, there are also different types of steel coil material handling equipment. These types will be further discussed in the following sections.
Coil reels are frequently used in uncoiling and recoiling applications because they prevent problems that involve stock deformation. In coil reels, the stock is supported on the coil’s center core and is unreeled as required. These reels are the best option for materials that are thin, prefinished, and are sensitive to marks. Coil reels are easily adapted to uncoiling and recoiling. They are also less costly as compared to coil cradles.
This type of equipment has weight capacities that range from lbs to lbs. The stock widths of coil reels also range from 12 inches to 84 inches. These coil reels have customized configurations (such as motorized or pull-off reels) that are best suited for your application.
For example, motorized reels have controls in order to improve the drive response for the material that is being worked on. Like cradles, reels are made out of materials and components that are heavy duty and durable.
Cradle-type uncoilers have the advantage of easy and fast loading of coils. Coil cradles are usually used along with coil straighteners in order to have lower power requirements and maintenance. Coil straighteners are made to remove coil set and cross bow, as well as to pay out material to the accumulation loop for the feeder. Straighteners that range from five to seven rolls are used for most materials and flatness requirements.
Cradles can be used as a separate uncoiler or can be used in combination with a straightener in order to form a cradle-straightener. Load capacities of this equipment ranges from to lbs. They can handle stock widths that range from 12 inches to 84 inches.
Coil cradles are more suited to process thick materials, are self-contained, and are easy to set up and relocate.
Standard features of cradles include an expansion that is either wedge or link type, a machine that is manual or hydraulic, pillow block bearings, coil keeper arms, and loop controls with different speeds.
Disadvantages of using coil cradles include the possible difficulty of rewinding unused material. They are also not recommended for use with thin materials.
Advantages of coil stackers include lower employee costs, minimized scrap as well as floor space, more uptime, and balanced packs.
Standard features of stackers are magnetic and vacuum options, buttons for width and length adjustment, buttons for scrap discharge as well as side/ end pack discharge, and fast speed. For surface critical materials and sheets, stackers have non-marking rollers and an air float cushion.
Various types of coil handling equipment are commercially available, as each equipment caters to a specific industry and/ or type of coil to be handled and processed. Each of the equipment mentioned in this page will have a separate article and will be thoroughly discussed.
http://www.metformintl.com/products/individual-equipment/automatic-stackers-for-metal-forming-equipment.html
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http://www.cpec.com/equipment.html
http://www.thefabricator.com/article/stamping/straightening-mistakes
Steel Coil Processing is the transformation of steel coil into usable formats such as sheets, plates, or narrower coils, tailored to meet specific industrial requirements. This involves several key steps, including decoiling, straightening, slitting, and cutting to length, ensuring the material is accurately prepared for subsequent manufacturing. It is crucial for optimising material handling and enhancing production efficiency across various sectors.
Steel coil slitting turns large coils into manageable, precisely dimensioned products that meet stringent standards. This technique is especially valuable for producing high-quality sheet metal with improved flatness and reduced coil set, making it suitable for a wide array of industrial applications.
Steel coil processing plays a fundamental role in industries such as automotive, construction, and household appliances. The ability to cut, flatten, and straighten coils with precision results in lower production costs, reduced material waste, and enhanced operational efficiency.
Processed coils improve the usability of raw steel, enhancing supply chain performance and product consistency. These benefits establish coil processing as a cornerstone of efficient, cost-effective manufacturing compared to traditional sheet metal processing.
1. Cut-to-Length (CTL): Produces steel sheets or plates by cutting coils to predetermined lengths. Industries such as construction, automotive, and manufacturing rely on this method for precision sheet metal.
2. Slitting (Cut-to-Width): Cuts coils lengthwise into narrower strips, making them suitable for roll-forming, stamping, or other applications requiring specific widths.
Coil processing employs specialised equipment including decoilers, straighteners, slitters, and levellers. A key component is the coil slitter machine, which slices coils into narrower strips with precision, maintaining consistent widths while minimising material loss.
Modern coil processing machinery incorporates automated systems and advanced press feed technologies. These integrated coil processing lines streamline operations such as loading and unloading, leading to higher productivity and reduced labour costs.
Coil slitting involves cutting steel coils lengthwise using horizontal blades, producing narrower strips suited to specific applications. This method relies on a coil slitter machine designed to maintain strict width tolerances and minimise defects such as edge wave.
Slit coils are essential in the production of components for cable trays, vehicles, and other sheet metal applications. By reducing raw material waste and improving yield, coil slitting contributes significantly to manufacturing efficiency and cost-effectiveness.
Cut-to-length (CTL) processing involves uncoiling, straightening, and cutting steel coils into specific sheet or plate lengths. This method removes imperfections such as coil set and produces flat, uniform pieces suitable for construction, automotive, and fabrication industries.
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CTL delivers multiple advantages, including precise dimensions, improved flatness, and simplified handling and storage. As a core coil processing method, it ensures the delivery of high-quality, ready-to-use steel products.
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Located in the Midlands, our state-of-the-art facility houses an advanced Durmech mm slitting line, capable of precision slitting coils with gauges ranging from 0.7mm to 6.0mm across multiple steel grades. This technology enables us to oversee the entire tube manufacturing process from start to finish, ensuring quality and efficiency. In addition to slitting, our site also offers ERW Manufacturing, Tube Laser Cutting, Slotting, and more.
Currently, we process around 45,000 tons of coil annually, with the infrastructure in place to expand this capacity to 60,000 tons per year. Our facility can handle coils weighing up to 25 tonnes and widths up to mm, allowing us to cater to a diverse range of customer needs.
We prioritise quality in every aspect of our operations. By sourcing steel globally and closely monitoring market trends, we secure high-quality materials at competitive prices. Our processed strip meets stringent industry standards, including:
● Hot Rolled: DD11, S235, S275, S355
● Cold Rolled: DC01 – DC04
● Galvanised: DX51, S280, S350, S390
● Aluminised: DX51, DX52, DX53, DX54, DX55
This diverse selection of steel grades highlights our adaptability and commitment to meeting the needs of various industries and applications.
While a large portion of our slit coil is utilised internally for further manufacturing, we also supply a significant volume directly to customers.
These slit strips play a crucial role in producing components for presswork, section rolling, re-rolling, automotive exhausts, heating appliances, washers, and security solutions such as fencing and palisade fencing.
Material Strength and Durability – Steel coils provide exceptional strength and durability, making them suitable for applications requiring resistance to high temperatures and pressures.
Reduced Material Handling – The continuous coil feeding process eliminates the need for constant manual loading and unloading, saving time and reducing labour costs.
Cost-Efficiency – Coils are often more cost-effective than individual sheets, and the efficiency of coil processing further lowers overall manufacturing expenses.
Increased Production Speed – Our feeding systems in coil processing significantly enhance production speed compared to traditional sheet processing, reducing downtime & increasing output.
Corrosion Resistance – Certain types of steel coils feature coatings that enhance corrosion resistance, making them ideal for harsh environments and long-term applications.
Versatility – Coil processing accommodates a wide variety of applications, including automotive parts, construction materials, and household appliances.
Diverse Industrial Applications – Coil processing supports various industries, including:
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Customer-Centric Service: We offer tailored delivery options and responsive customer support, ensuring a seamless experience.
Versatile Applications: Our slit coils serve a broad spectrum of industries, evidencing our flexibility and the trust our customers place in us.
Global Sourcing and Quality: Our proactive approach to sourcing ensures access to high-quality materials at competitive prices, supporting the delivery of superior products.
Capacity and Flexibility: With the ability to process up to 60,000 tons per annum and accommodate wide and heavy coils, we can meet high-demand requirements.
Automotive
Essential for producting body panels and chassis components.
Home appliances
Refrigerators, washing machines, and ovens.
Water Industry
Ensuring high-quality, durable steel components of tanks and pipelines.
Construction
Pre-engineered buildings, cable trays, and roofing sheets.
Coil processing, including precision slitting, is a fundamental step in steel manufacturing, providing industries with cost-effective, high-quality materials tailored to their needs. With advanced technology, global sourcing, and a strong commitment to quality, our coil slitting services support a wide range of applications, ensuring efficiency and consistency in industrial production.
Our expert team is ready and willing to assist you with all your manufacturing needs, simply click the link.
If you are looking for more details, kindly visit Coil Processing Equipment.