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 pre–galvanised 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.
Keystone YAWCI


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Optimised Operators Headcount per Line

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Reduced Energy Consumption

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Elimination of Rework & Re-galvanising

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Minimised Total Cost of Operations

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. 



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.

Kaystone lintels

The Solution consisted of:

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Adaptable Lintel Conveyor Systems for Varied Lintel Dimensions
Polystyrene Insertion Station
Thermal Break Plate Pick, Tang & Place Station
Press to Plate Puck picking buffer (15 mins capacity)
Press to puck loading system Pick and Place and press interface
Integrated Clinching Station
Integrated Perforating and Lip Rolling Station
System Safety & Guarding
Line Control System
Automated Smart Indexing

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. 

Keystone YAWCI


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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