Roll-Out Sheet Racks Compliment Laser Processing

You invested in a CNC laser for its speed and precision. But is your material handling system now the bottleneck? This was the exact challenge facing a major electrical enclosure manufacturer in Kentucky. They discovered that an automated storage tower, once a high-tech solution, couldn’t scale when a second laser was added to their production line. The system was overwhelmed, creating a choke point that threatened to idle two massive capital investments.

Their solution? Replacing the rigid automation with the dynamic, human-centric efficiency of eight Herochu Roll-Out Sheet Racks.

This case study isn’t an anomaly; it’s a blueprint for modern manufacturing. It reveals a fundamental truth: maximum laser output isn’t just about the machine’s cutting speed. It’s about creating a seamless, uninterrupted flow of material to the machine. This is where the Herochu Roll-Out Sheet Rack system transitions from a piece of workshop equipment to a strategic production catalyst.

The Kentucky Blueprint: A Masterclass in Cellular Manufacturing

The Kentucky plant’s setup is a perfect model of efficient workshop design. They didn’t just place racks near their lasers; they created a dedicated manufacturing cell.

• Strategic Arrangement: The eight racks were arranged in a “single battery” – a unified block – with all roll-out drawers facing the lasers directly.

• Operator-Centric Design: This layout meant laser operators never had to take their eyes off their workstations. The material was literally at their fingertips.

• Optimized Work-in-Process (WIP): The forty-six drawers became a dynamic buffer, holding precisely the sheet metal (up to 5′ x 10′) needed for the enclosures, organized and ready for action.

The result was a material flow that finally kept pace with the machines, maximizing the output of both lasers and validating the entire production expansion. This successful implementation highlights the core philosophy of the Herochu system: it compliments laser processing by becoming an integrated, responsive part of the workflow, not a separate, isolated function.

The Anatomy of Efficiency: Front-Access Retrieval, Rear-Load Replenishment

The Herochu system operates on a brilliantly simple dual-access principle that separates the workflows of retrieval and replenishment, eliminating conflict and delay.

1. The Front Line: Laser Operator Retrieval
At the front of the rack, the operator’s world is transformed. The integrated pull-out drawer design means no more waiting for a forklift, no more awkward maneuvering, and no more digging through stacks. An operator, using an overhead crane with a vacuum lift, can:

• Glide a fully loaded drawer open with minimal effort.

• Identify and secure the exact individual sheet needed.

• Transfer it directly onto the laser table in one fluid motion.

This process takes mere seconds, ensuring the laser spends more time cutting and less time waiting. The “convenient and immediate access” cited in the case study is the direct result of this human-centered engineering.

2. The Support Line: Forklift Replenishment
While operators work at the front, material handling staff work in parallel at the rear. The Rear-Load Drawer design allows a forklift to load entire bundles of sheet stock from the back aisle without ever interrupting the laser operators at the front. This separation of traffic is critical for both safety and continuous operation.

The Genius of the “Empty Drawer” Signal: Proactive Workflow Management

A particularly innovative feature of the Kentucky installation is the flashing light indicator for empty drawers. This simple yet powerful addition transforms the system from a passive storage unit into an active workflow communicator.

• Eliminates Guesswork: The laser operator no longer needs to radio the warehouse or make a note to replenish a specific material. The visual signal is an instant, unambiguous broadcast of need.

• Enables Proactive Replenishment: The forklift operator can see the signal from a distance and plan their next task accordingly, fetching the required stock without a formal request, thus smoothing the overall logistics chain.

• Prevents Production Stoppages: This continuous feedback loop ensures that drawers are refilled before a specific material type runs out completely, preventing the number one cause of unplanned downtime: material shortage at the point of use.

This feature exemplifies how the Herochu system is designed not just to store, but to communicate and facilitate.

Engineered for Performance: The HC Series Standard Models

The Herochu system is built on a platform of robust, standardized engineering, with models like the HC-B series designed to meet common industry needs while offering a clear path to full customization.

Let’s deconstruct the HC-B4020-65 model as an example:

• Model Code: HC (Herochu Constant) B (Board Type) 40 (4000mm Plate Length) 20 (2000mm Plate Width) 65 (6 layers, 5-ton capacity per layer).

• Load Capacity: A formidable 5 tons (10,000 lbs) per drawer. This allows for the storage of thick steel plate or stacks of lighter-gauge material without a second thought.

• Plate Size: Optimized for 4000mm x 2000mm sheets, a common industrial size.

• Number of Layers: The 5+1 configuration provides six distinct storage levels, offering excellent density without compromising accessibility.

• Ground Clearance: A 355mm clearance at the bottom layer facilitates easy cleaning and allows for integration with floor systems.

• Integrated Pull-Out Mechanism: This isn’t a simple drawer slide. It’s a heavy-duty, integrated system engineered to bear the immense weight while allowing smooth movement, requiring a manageable force to initiate and stop, ensuring control and safety.

Other standard models, like the HC-B3015-63 and the larger HC-B6020-66, offer a range of options for different shop floor footprints and material sizes. The external dimensions are precisely calculated to provide a stable, balanced structure, with a top floor height that keeps all storage within a practical reach for overhead cranes.

The Customization Imperative: Your Process, Your Rack

While the standard models are powerful, the true strength of Herochu lies in its flexibility. The “Customized” column in the specifications isn’t an afterthought; it’s a commitment.

• Load Capacity: Do you work primarily with aluminum or titanium? We can engineer a system with a customized load per layer, scaling from the standard 3t to a colossal 15t or more, ensuring you never pay for over-engineering or risk under-specifying.

• Plate Size & Number of Layers: Whether your laser processes compact 3000mm sheets or massive 8000mm plates, the rack can be built to match. We can configure the number of layers and the height of each partition to perfectly suit your material mix, from thin gauge to thick plate.

• Seamless Integration: We design for your specific workflow. The rear-load/front-access design can be adapted to your facility’s unique layout, ensuring the racks fit your space and process like a glove.

The Tangible Return on Investment: More Than a Price Tag

The starting price of $5,199 is an investment in quantified productivity gains. The Kentucky case study provides the evidence:

1. Elimination of Bottlenecks: By replacing the overwhelmed storage tower, they removed the critical constraint holding back their two lasers. This directly increased the return on investment for both laser systems.

2. Labor Optimization: Laser operators focus on laser operation. Forklift drivers focus on bulk replenishment. The Herochu system defines these roles clearly, reducing cross-traffic and task-switching, which boosts morale and efficiency.

3. Space Utilization: A well-organized battery of racks provides far greater accessible storage density than scattered stacks or inefficient automated systems, effectively creating more usable floor space.

4. Safety and Damage Reduction: Controlled, individual sheet retrieval via crane drastically reduces the risk of plate damage from scratching or forklift mishaps, and more importantly, minimizes manual handling injuries.

A Foundation of Trust: CE, UE, and ISO 9001 Certification

In an industry where failure is not an option, third-party validation is non-negotiable. The Herochu Roll-Out Sheet Rack system is CE, UE, and ISO 9001 certified. This means every weld, every bearing, and every structural calculation has been executed under a quality management system that meets the most rigorous international standards for safety, design, and manufacturing consistency.

Stop letting your material storage dictate your laser’s productivity. Embrace the system that compliments your high-tech machinery by providing a equally sophisticated, responsive, and robust logistics backbone.

Contact us today for a consultation. Let’s discuss your specific laser cell, your material challenges, and how a customized Herochu Roll-Out Sheet Rack system can become the engine of your uninterrupted production.