Curbed ‘Roofing’ Manpower Dependence


Accelerated Production line

Curbed ‘Roofing’ Manpower Dependence

Setting The Scene

Keystone Lintel Limited, a leading manufacturer of steel lintels and roofing solutions. At their Derbyshire facility, they produce a wide range of lintel variations from high grade pregalvanised mild steel with a zinc coating of 600g/m². With an extensive product line-up and a labour-intensive manufacturing process, the company faced challenges in terms of manpower requirements and energy consumption. 

Optimised Operators Headcount per Line

Reduced Energy Consumption by Eliminating Welding

Elimination of Rework & Re-galvanising

Minimised Total Cost of Operations

Keystone embraces automation,
paving the way for a more efficient and sustainable future


The Challenge

Keystone Lintels produced 122 variations of lintels, with length varying from 750mm to 4.8m, material thickness from 1.6mm to 3.2mm, 3 cavity widths, 2 outer leaf lengths and 132 different types of insulation. 

It required multiple production lines and extensive manual labour. This process involved shaping the lintels using press brakes and performing insulation fitting, welding, and galvanised painting. The existing production method demanded significant manpower and consumed substantial energy, hindering operational efficiency. 

Integrated Perforating and Lip Rolling Station

The Solution

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.
The Solution consisted of:


The Benefits

The new production line achieved remarkable outcomes for Keystone Lintels. With a production rate of 4.8 meters of lintels every 27 seconds, the line had the capacity to produce 6,665 lintels and 21,300 break plates in a 10-hour shift. The significant reduction in manual labour required to produce a single lintel was a key benefit, streamlining operations and improving overall efficiency.

The adoption of clinching technology eliminated the need for spot welding, reducing energy consumption and eliminating the necessity for post-galvanized coating. This resulted in cost savings and an improved workplace environment. 

Optimised Operators Headcount per Line

Reduced Energy Consumption by Eliminating Welding

Elimination of Rework & Re-galvanising

Minimised Total Cost of Operations

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Accelerated Production

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