Setting The Scene

Flexeserve are industry leaders in designing, manufacturing, and providing hot-holding and food-to-go solutions to their customers. With increase in demand for their solutions and services, Flexeserve wanted to deploy an automated production and material handling solution that would help optimise operations, improve ergonomics, and increase throughputs. The automated solution provided by L-A-C consisted of two new mechanised production lines equipped with an inline automated pallet conveyor system. The system comprised of four ergonomic assembly stations, three buffer stations and one offload station.


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Shorter Cycle Time

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Reduction in Manual Movement

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1.5x Productivity Increased

The Challenge

L-A-C successfully delivered two pallet conveyor-based production lines that effectively tackled the challenges faced by Flexeserve. The customised solution incorporated a pallet loading ramp, height-adjustable workstations, and buffer stations to ensure smooth and independent progression of products through the production line. 


Operators could easily adjust heights using automated controls and utilise a work complete button for task completion. Buffer stations minimised operator wait time, while the unload station facilitated manual offloading after final assembly. 


The CE certified system accommodated different pallet types with safety measures in place. Each line, integrated with the scissor lift achieved a remarkable throughput of 60 pallets per 8-hour shift, surpassing manual operations. 


Overall, the project successfully improved productivity and efficiency in the assembly line, fulfilling the desired objectives. successfully improved productivity and efficiency 

Flexeserve uk


To address these challenges, a semi-automated production line was developed, integrated with the existing automated press brake folding line. The new production line featured an insulation loading station, guided by screens that directed operators on insulation placement. 


Two insulation presses ensured precise positioning of insulation within the lintel cavity. A break plate punch system transformed a steel coil into individual plates, which were then stacked and transported by a conveyor system to a pick and plate cell. 

This cell picked the plates, performed necessary punching, and pierced the insulation in the lintel. The lintels continued through a roll forming station for perforations and outer lip formation before reaching the end of the line for operator offloading. 


Keystone Lintels achieves a remarkable 4.8 meters of lintels every 27 seconds, streamlining operations and boosting efficiency.

Flexeserve conveyor system

The Solution consisted of:

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Pallet Conveyor based production line
Loading and unloading stations
Customised and Height Adjustable Workstations with automated controls
Buffer sections
Hymo Scissor Lift
PLC & HMI based controls

The Benefits

The implementation of L-A-C’s automated solution has brought significant benefits to Flexeserve. The streamlined production lines, height-adjustable workstations, and buffer stations have improved efficiency, reduced cycle times, and minimized operator fatigue. 


The system’s impressive throughput surpasses manual operations, enhancing productivity. Overall, L-A-C’s solution has provided Flexeserve with a highly efficient assembly line, enabling faster delivery of their solutions and services to meet increasing customer demands. 

Flexeserve uk



L-A-C’s team of experts are here to support you from concept to the finished system, working together to design and deliver a bespoke solution that meets your current objectives and future growth expectations, with favourable ROI. 


Across semi-automated and fully automated systems, L-A-C has the expertise and range of products to provide flexible and scalable solutions that will significantly enhance your operations and keep you agile as your business evolves. 


Join us on a pivotal journey towards a more efficient, productive, cost effective and sustainable future with L-A-C’s innovative automation technology solutions.

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