Automated Tool Loading for Coil Slitting Lines
STAHL automates the complete tool handling process, transforming time-intensive manual operations into fast, consistent workflows. Every setup is executed to the same standard, helping reduce variation between shifts and minimise setup-related errors.
Slitter tool handling is one of the most demanding tasks in coil processing
Handling slitter tools is a critical part of coil processing, but it is also one of the most repetitive, physically intensive, and precision-sensitive operations on the line.
Operators must manage heavy components, maintain exact sequencing of knives and spacers, and execute setups with high accuracy under time pressure. Even small inconsistencies can impact strip quality, production flow, and material yield.
Maintaining this level of precision consistently, shift after shift, places significant demands on both the process and the working environment.
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When tool handling is not properly managed, performance suffers
In manual environments, maintaining the same level of precision, speed, and control across every setup can be difficult.
Precision becomes harder to control
Clearance between knives may vary from one setup to the next, increasing the risk of scrap and rework, especially on premium materials.
Changeovers become less predictable
Speed and accuracy can fluctuate across shifts, making output harder to predict and daily capacity more difficult to plan.
The working environment becomes more demanding
Handling heavy tooling every day creates a physically demanding environment where repetitive strain and injury risk become important operational concerns.
Skilled labor gets pulled into repetitive tasks
Skilled operators often spend valuable time on repetitive manual handling instead of focusing on higher-value technical and production tasks.
Meet STAHL: Precision-Automated Slitter Tool Management
See how STAHL fits your operationSTAHL is an automated system designed to manage slitter tool storage, handling, inspection, and loading as one integrated process.
Built for coil slitting operations, it introduces structure and repeatability into one of the most demanding stages of production. By reducing reliance on manual coordination, STAHL helps create a more stable, efficient, and predictable foundation for slitting operations.
STAHL vs. Manual Operations vs. Traditional Robots
| Model | Manual Operators | Traditional Robots | Stahl Recommended |
|---|---|---|---|
| Format Change Time | 30–45 min | 30–45 min | 25–30 min |
| Floor Space Required | Space for tool racks | W × L |
0.54×W×L (linear) 0.33×W×L (circular) |
| Knife Condition Tracking | Visual inspection | Basic laser, no data logging or tool ID tracking | 2µm laser measurement |
| Works Around Obstacles | Yes | No (rigid layout) | Modular layout |
| Tool Life Management | Operator judgment | Basic scheduling | Data-driven selection |
| 24/7 Operation | Requires 3 shifts | Yes | Yes |
What STAHL brings to your
slitting operation
Discuss your slitting line with an expertSTAHL brings greater precision, consistency, and control to slitter tool handling. It manages the complete tool lifecycle, from storage and handling to inspection and loading, while supporting tool thicknesses from 1.0 mm.
The result is a more stable process that helps improve setup accuracy, protect cut quality, and support smoother day-to-day operations.
Protect your margins with consistent setup accuracy
Achieve repeatable precision on every tool setup. Clearance between knives remains consistent across setups, delivering quality consistency that protects your margins on premium materials. No sequence errors in rubbers and knives. Helps reduce the risk of setup-related material loss.
Extend knife life with data-driven tool selection
Tracks tool condition and usage history automatically: which tools were last sharpened, which combinations optimise specific jobs, and when replacement is due. Data-driven tool selection extends knife life while maintaining consistent cut quality across every production run.
Give your team more time for higher-value work
By handling repetitive tool management automatically, STAHL allows skilled operators to focus on quality control, process oversight, and other technical priorities. The result is a more stable and predictable production flow across every shift
Fits your layout, not the other way around
STAHL’s modular design adapts to your facility and works around structural constraints such as pillars and passageways. It integrates with your existing slitter and turnstile without requiring major modifications.
Two Configurations for Every
Slitting Operation
STAHL is available in two layout designs, each optimised for
different tool sizes and facility constraints.
| • STAHL-2 (Linear) | |
|---|---|
| Tool OD Range | 508–660 mm |
| Best For | Heavy gage |
| Layout Type | Linear |
| Floor Space vs Competitors |
0.54 × W × L (54% of traditional robot footprint) |
| Setup Assembly Cycle | ~20 min |
| • STAHL-3 (Circular) | |
|---|---|
| Tool OD Range | 305–508 mm |
| Best For | Light gage |
| Layout Type | Circular |
| Floor Space vs Competitors |
0.33 × W × L (33% of traditional robot footprint) |
| Setup Assembly Cycle | ~17 min |
See STAHL in Action
How STAHL Works
Plan your STAHL implementation
Automatic Unloading
- Robot extracts used tool setup from turnstile
- Separates sticky tools automatically
Precision Inspection (add-on configuration)
- Laser profiler measures knife edge wear to 2μm
- Detects defects as small as 50μm
- Reclassifies tools based on conditioN
Industrial Washing (add-on configuration)
- Ultrasonic cleaning with heated alkaline detergent
- Passivation rinse and air-knife drying
- Handles multiple tools simultaneously
Intelligent Storage
- Warehouse management system tracks each tool
- Associates wear data with tool ID (DPM scanning)
- Stores in modular vertical carousels
Optimal Tool Selection
ERP/MES integration pulls production order data DSS (Decision Support System) selects best setups based on:
- Material hardness
- Strip thickness
- Quality requirements
- Knife wear equalisation strategy
Automatic Loading
- Robot assembles new setup with perfect clearances between knives
- Loads onto turnstile ready for production
Proven Results Across 20+ Installations Worldwide
Explore Technical
Resources
Get detailed product documents that outline the specs, features and configuration of MAKE’s coil slitting solutions
Frequently Asked Questions
The installation requires the slitter turnstile only for the first 2 days during which the robot base is aligned. Except for these 2 days, the slitter can be operated manually during all of the installation. Total timeline is approximately 2 weeks of installation and 2 weeks of commissioning and startup support.
Yes, STAHL retrofits to any slitter with a tool loading turnstile. We’ve installed on Salico, Novastilmec, Camu, Georg, and all major brands.
Our modular carousel system is designed for this. We can configure around obstacles that would prevent traditional robot installation.
Our laser profiler has 2 micrometer repeatability — far beyond human visual inspection.
You’ll need one operator for overall supervision, but once the robot is set they can be dedicated to other activities. STAHL handles the dedicated tool-handling work.
Absolutely. We offer facility tours at reference sites, and can arrange video demonstrations tailored to your specific application.
The largest tools we have handled were OD = 660 mm, but larger diameters can be accommodated.
The same way it handles knives and spacers — fully automated pickup, placement, and sequencing.
8 setups per shift.
The installation requires the slitter turnstile only for the first 2 days. The slitter can be operated manually during the rest of the installation period.
Depending on the diameter of the tools, the robot can store up to 69,300 mm of tools on 198 pins.
STAHL can handle any tool thickness from 1.0 mm.
STAHL-2 uses a linear carousel layout designed for heavy gage lines with tool ODs from 508–660 mm. STAHL-3 uses a circular carousel layout for light gage lines with tool ODs from 305–508 mm. Both share the same automation capabilities — the difference is physical layout and tool size range.
Find Out Your Potential Savings with a STAHL Specialist
Find out if STAHL makes sense for your operation. We’ll discuss your current format change process, assess layout feasibility, and outline realistic benefits — all in a 20-minute conversation.
Here’s what we’ll cover:
• Your current process and bottlenecks
• Realistic benefits for your specific operation
• Layout requirements and installation timeline
• Next steps if the numbers make sense
Fill in the form and our team will get back to you shortly.
