Project Overview
Transicon’s mechatronics team developed and integrated an automated loop doubling system to increase processing continuity on a high-throughput slitting line at a UK-based automotive metals facility.
The solution addressed a core limitation in the handling of large-gauge coils — enabling full coil processing without interruption, reducing material waste, and supporting greater line efficiency.
The Challenge
The customer was operating a 22.5-tonne coil-fed slitting line, but due to strand variation and handling limitations, only around 12 tonnes of thinner-gauge material could be processed in a single run.
This led to:
- Interrupted production runs
- Significant underutilisation of material
- Increased scrap and changeover time
The brief was to find a way to enable uninterrupted processing of full coils without major structural changes to the line.
The Solution
Rather than modifying the core machine structure, Transicon engineered a loop doubling system that could adapt to the physical constraints and operating parameters already in place.
Key features of the solution included:
- Mechanical redesign of the loop system to accommodate greater coil length
- Electrical and control system modifications to support smooth feed transitions
- Real-time feedback and automation logic to manage variable strand tension
- Integration with existing safety and operational infrastructure
This was delivered as a combined mechanical, electrical and software project — designed in-house by Transicon’s mechatronics division and installed with minimal disruption to live operations.
Technical Outcome
- Full 22.5-tonne coils can now be processed without pausing for re-threading
- Reduced waste and improved material utilisation
- No significant downtime during installation or commissioning
- Existing machine hardware retained — minimising cost and complexity
Need Something Similar?
This project is one example of how Transicon works with customers to solve complex, bespoke automation challenges — using a practical, engineering-led approach to deliver measurable results.
If you’re facing a production or process bottleneck and need a solution that fits your existing infrastructure, we’d be happy to help.
Contact us to talk through your requirements.
