Automated Sheet Metal Material Storage Systems – Herochu Single & Double Tower

Automated sheet metal material storage systems have moved beyond simple racking to become intelligent nodes in the digital factory. Herochu’s RRW series delivers two architectures—single-tower and double-tower—each optimized for different sheet dimensions, throughput requirements, and budget constraints. Both systems share common attributes: steel construction, powder coating for corrosion and ESD protection, screw assembly for reconfigurability, and 8-layer configurations with adjustable bay heights.

Core Technology: Single-Tower vs. Double-Tower

The single-tower RRW model handles sheets up to 4000×2000 mm or, in an extended version, up to 8000×2500 mm. Each level supports either 3 tons or 5 tons, selectable at order time. The tower operates with a single hoist that services all levels. This configuration is ideal for small to medium warehouses where storage density matters more than throughput speed.

The double-tower sheet metal storage series, by contrast, uses two adjacent towers sharing one hoist mechanism. The front tower’s lower levels connect to a loading station and a lifting mechanism, forming a buffer storage zone for material pallets. This buffer allows the hoist to deposit incoming sheets into the rear tower while simultaneously retrieving from the front tower. Compared to two independent single-tower systems, the Herochu double-tower design reduces equipment cost by approximately 25% while maintaining similar retrieval rates.

Advanced Material Handling Features

Both configurations integrate sheet separation and double-sheet detection as standard functions. The separation mechanism uses air knives or mechanical lifters to ensure that only one sheet is picked from a stack. Double-sheet detection employs ultrasonic or capacitive sensors that trigger an automatic retry cycle if two sheets are lifted together. These features are critical when the storage system feeds directly into a laser cutter or a punch press, where double feeding causes tool damage and scrap.

The powder-coated surface treatment on all steel components provides three layers of protection: a zinc phosphate primer, an epoxy powder coat, and a clear topcoat for additional anti-rust performance. This multilayer finish withstands workshop humidity, oil mist from machining operations, and incidental contact with cutting fluids. ESD protection is built into the tray surfaces to prevent static discharge that could damage coated or anodized sheets.

Modular Design and ERP/MES Integration

Herochu engineers the RRW series for modular expansion. A single tower can operate standalone, managed by its own touchscreen panel. When production demands increase, additional towers can be added alongside, sharing the same rail system and hoist. The double-tower model accepts third-party auxiliary equipment such as automatic sheet feeders, deburring stations, or stacking robots. All communication uses standard industrial protocols—Profinet, EtherCAT, or Modbus TCP.

ERP and MES connectivity is expandable through a middleware gateway that translates material requests into storage commands. For example, when an MES system schedules a cutting job for 3mm mild steel, it sends a material ID to the storage controller. The controller locates the corresponding tray, retrieves it to the loading station, and signals the MES when the sheet is ready. This closed-loop communication supports 24/7 continuous operation without human intervention. Herochu has validated the interface with major ERP brands including SAP, Oracle, and Infor.

Safety and Compliance

Each RRW system carries CE and ISO certifications. Safety features include interlocking doors that prevent access during hoist movement, overload detection on the lifting motor, and anti-drop brakes on all moving parts. The screw assembly method allows for easy replacement of damaged rails or trays without dismantling the entire tower. A full set of drawings and torque specifications is provided for in-house maintenance teams.

The corrosion protection extends to fasteners: all screws and nuts are zinc-plated grade 8.8 steel. This prevents seizing in humid environments and simplifies future reconfiguration. Foldable components in the shelf supports reduce shipping container usage, lowering the carbon footprint of delivery.

Performance Data and Use Cases

In a recent installation at a German automotive parts supplier, a double-tower RRW system stored 80 pallets of high-strength steel sheets ranging from 1.0mm to 4.5mm. The facility operated three shifts, processing 1200 sheets per week. The automated sheet metal material storage system reduced forklift traffic by 70% and eliminated sheet damage caused by fork tines. Retrieval accuracy reached 99.8%, with the 0.2% errors traced to barcode misreads that were corrected by adding RFID backup.

Another case involved a Chinese HVAC manufacturer storing aluminum sheets of 3000×1500mm. The single-tower model with 5-ton layers allowed them to consolidate four floor-stacked piles into one tower, freeing 200 square meters for additional assembly lines. The anti-rust property proved essential because aluminum stored in humid conditions develops white rust that compromises brazing quality. After one year of operation, the reject rate from brazed joints dropped by 45%.

Economic Justification

Calculating return on investment for automated sheet metal material storage systems involves three factors: floor space savings, labor reduction, and material damage reduction. A typical single-tower RRW occupies 6m² of floor space but provides the equivalent storage of 50m² of floor stacking or 30m² of conventional pallet racks (including aisles). Labor savings come from eliminating forklift-based retrieval and inventory counting. Material damage reduction alone often pays for the system within 18 months in high-volume shops.

Herochu offers a leasing model that includes installation, training, and one year of remote support. The screw assembly design means the system can be moved to a new site for a fraction of the original installation cost, preserving asset value.

Conclusion

Herochu’s RRW series—comprising single-tower and double-tower automated sheet metal material storage systems—provides a flexible, certified, and durable solution for modern sheet metal warehouses. With powder-coated steel construction, 8 layers, 5-ton capacities, screw assembly, and ERP/MES readiness, these systems deliver measurable improvements in density, speed, and safety. The double-tower variant adds cost efficiency through shared hoist and buffer zone design, making automated vertical storage accessible to smaller fabricators.