The Ultimate Lean Coil Fabricating System for Drywall Profiles: COIL TO PACK

January 2025 Rollforming

Maximizing Efficiency, Reducing Costs and Embracing Lean Manufacturing

Dallan has revolutionized drywall profile production with its innovative COIL TO PACK system.

Specifically designed for “Stud and Track” profiles, this system combines cutting-edge roll forming technology with a fully automated packaging solution, achieving unparalleled productivity and cost savings.

Key Performance Metrics: Efficiency Redefined

The COIL TO PACK system delivers a production capacity of 33,000 meters of profiles in just 8 hours, requiring only one operator.

In contrast, traditional systems with manual packaging struggle to reach 20,000 meters per day, demanding multiple operators.

This remarkable efficiency translates into substantial annual savings, generating $490,000 USD in net profit solely from labor cost reductions.

Core Lean Manufacturing Principles Integrated

This system embodies the essential principles of Lean Manufacturing, making it the ultimate choice for drywall profile production:

Material Optimization: Minimal waste and maximum utilization of coil material.
Labor Minimization: Requiring only one operator for the entire system.
Maximum Productivity in Minimal Space: Compact design with high throughput.
Just-In-Time Production: Profiles are produced as needed, eliminating intermediate storage.
Elimination of Intermediate Warehousing: Streamlined processes for a seamless workflow.

Advanced Features and Technologies

High-Speed Roll Former:
- Operates at up to 120 meters per minute.
- Designed for precision and consistent quality.
Dallan A12W Automatic Packaging System:
- Automatically creates large, secured master packs.
- Applies wooden slats under the bundles, ensuring operators can handle them without leaving the forklift.

The Competitive Advantage

By adopting the Dallan COIL TO PACK system, manufacturers benefit from:

Drastically Reduced Labor Costs: Labor savings alone significantly improve profitability.
Increased Output: Almost 70% higher daily production compared to traditional systems.
Improved Operator Efficiency: Simplified handling processes streamline operations.

Seeing Is Believing: Experience the Difference

We invite you to visit us and witness the system in action.

Collaborate with our engineers to explore case studies tailored to your production needs and calculate the savings your business can achieve with this system.

A Step Towards the Future of Lean Manufacturing

The COIL TO PACK system represents a leap forward in drywall profile production, empowering businesses to enhance productivity, reduce costs, and adopt sustainable manufacturing practices.

With its integration of Lean principles and advanced automation, this system is more than just a machine—it’s a strategic investment in operational excellence.

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