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Case study / Food and Beverage

Helping American Panel Increase Blanking Speed and Quality with a Next-Generation COE Cut-to-Length Line

American Panel

Project overview

Visionary Manufacturing Solutions supported American Panel, one of the largest walk-in refrigeration manufacturers in the United States, with a new COE cut-to-length line for producing blanks used in walk-in cooler manufacturing. American Panel had purchased its first COE line in 2009, installed in 2010, and the original system became a highly productive and profitable asset for their operation.

The COE cut-to-length line — coil reel, straightener and feed — on the American Panel floor

Order to install

11 months

From purchase order to a line producing blanks faster than expected after training.

Customer Challenge

American Panel’s production environment is high mix and low volume, requiring the team to cut blanks for the jobs they need to manufacture that day or the next day. Because jobs and materials change frequently, the customer needed a system focused on fast coil changeover, quick blank-to-blank transitions, reduced scrap, and consistent blank quality.

VMS Solution

Visionary helped provide a new COE cut-to-length line designed to build on the success of the customer’s original line while adding newer technology for speed, quality, and efficiency. The upgraded system included technology to support faster coil-to-coil changeover, improved blank flatness, scrap reduction, and easier operation through advanced controls.

Technology Highlights

The new line included modern COE precision straightening technology, Work Roll Advisor, coil outside-diameter monitoring tied into the straightener PLC, work roll adjustments on the fly, auto rewind crop shear functionality, a new servo shear to increase speed and reduce power consumption, and a redesigned PVC film applicator to help reduce scratches on the outside of blanks for downstream processing.

Project Execution

From order to installation, the project timeline was approximately 11 months. After installation, startup, and training, American Panel was able to begin producing blanks faster than expected, reinforcing the value of the upgraded line and the long-term confidence built from their original COE system.

Results

Key results
  • Built on the success of American Panel’s original COE cut-to-length line purchased in 2009 and installed in 2010.
  • Supported high-mix, low-volume blank production for walk-in cooler manufacturing.
  • Improved coil-to-coil changeover speed for frequent material changes.
  • Reduced scrap through upgraded line technology and automation.
  • Improved blank flatness with newer precision straightening technology.
  • Enabled work roll adjustments on the fly through advanced controls.
  • Reduced power consumption and increased speed with a new servo shear.
  • Helped protect blank surfaces with a redesigned PVC film applicator.
  • Completed order-to-install execution in approximately 11 months.
  • Helped American Panel produce blanks faster than expected after startup and training.

How our customers win

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