Post Machine Installation & Robotic Stacker Integration
for
Metroll
Installation of advanced post and rail forming machines with robotic stackers that doubled production output, including the relocation and recommissioning of three existing roll formers in just 1.5 days.
Overview
CPR Electrical completed the installation and commissioning of Metroll's new Post Machine, featuring advanced roll forming technology that produces fence posts and rails with robotic stacking — eliminating the need for constant operator interaction. The addition of robotic stackers doubled the productivity of these machines.
To accommodate the new machinery, CPR first decommissioned, relocated, and recommissioned three existing roll formers in just 1.5 days to keep production running. The new machine was then installed in a further 1.5 days, ready for immediate commissioning. Extensive Point to Point testing and Inspection Test Plans (ITP) ensured seamless operation.
Scope of Work
• Decommission, relocate, and recommission three existing roll formers
• Installation of new post machine with robotic stacker
• MCC termination and robotic controller integration
• Safety gate switch and operator console installation
• Comprehensive Point to Point testing and ITP compliance
Challenges & Solutions
Challenge
Installing new robotic production equipment while maintaining existing output required relocating three operational machines within an extremely tight 1.5-day window — any delay would directly impact Metroll's post and rail production schedules and downstream customer commitments. The robotic stacker integration added additional complexity, requiring precise coordination between electrical, mechanical and programming disciplines.
Solution
CPR developed a precision relocation plan enabling three machine moves in 1.5 days, followed by new machine installation in a further 1.5 days. Rigorous Point to Point testing and ITP compliance ensured all MCC, robotic controller, safety gate and operator console systems were verified before commissioning. The result was a seamless production transition that doubled Metroll's post and rail output capacity with zero commissioning issues.
Project Outcome
Three machines relocated in 1.5 days and new machine installed in 1.5 days with zero commissioning issues. The robotic stackers doubled Metroll's post and rail production capacity, delivering significant productivity gains.
Key Project Details
• Client: Metroll
• Location: Perth, WA
• Industry: Steel Manufacturing
• Project Type: Automation & Machine Installation
• Duration: 3 days (1.5 days relocation + 1.5 days installation)
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