Integrated Pallet Handling Conveyor System Upgrade for Automated Packing
Turnkey integration of pallet conveyor system for extremely heavy and hot spools of metal ribbon.
Engineering a safer, high-capacity workflow for metallic materials.
When Metglas, a leader in advanced metallic materials, needed a safer and more efficient way to handle extra-heavy, hot metal ribbon spools, they turned to Advanced Equipment Company (AEC). Led by Darin Boik, AEC’s President and Material Handling Specialist, the team engineered a turnkey integrated packing system that streamlined pallet product handling and pack-out operations without disrupting existing production workflows.
Increased worker productivity, better ergonomics, and increased plant capacity are just some of the benefits realized by Metglas after the integration of the Hytrol pallet conveyor and packing system.
Challenge: Eliminating the risks of a heavy, high-temp packing system.
The objectives were to provide a safe, ergonomic work environment, increase worker productivity, and increase plant capacity without changing the process. On the packing line, workers were manually moving pallets and relying heavily on forklifts.
This created a high-risk environment for back injuries, repetitive strain, and safety incidents. It also slowed the entire pack-out system, limiting throughput and forcing operators into non-value-added tasks. Additional hurdles included safely handling hot ribbon spools while reducing forklift congestion and maintaining system continuity.
Solution: Integrating a multi-stage turnkey pack-out solution.
AEC engineered a fully automated pallet handling system designed to improve safety, ergonomics, and efficiency. Darin Boik worked very closely with Barry Cates, Project Engineer at Metglas, and the Metglas team to form a solid partnership essential to the success of the new pack-out system.
A critical requirement was ensuring the packing system could not only move and stage pallets but also automatically stack, dispense, and apply labels to cartons. By integrating labeling into the process, powered by bar-code scanners and integrated with the Warehouse Management System (WMS), the solution eliminated manual labeling steps, increased throughput, and guaranteed every load was accurately tracked in real time.
- Pallet Conveyor System – Provided consistent, controlled movement of pallets through the packing line.
- Pallet Dispenser – Automatically supplied empty pallets into the line, eliminating manual staging.
- Pallet Collector – Removed completed loads for downstream movement, streamlining the end of the pack-out process.
- Vacuum Lifter – Enabled operators to handle hot, extra-heavy ribbon spools safely and with minimal strain.
- Monorail & Hoist System – Offered reliable overhead lifting in tight areas, reducing forklift dependency and ensuring controlled movement of heavy loads.
- Toledo Scales – Integrated weighing into the conveyor line for accuracy and speed.
- Bar-Code Scanners – Automated product identification and tracking, streamlining pack-out operations.
- Central Control & WMS Interface – Linked the pack-out system to warehouse software for real-time visibility and improved plant coordination.
Result: A Safer, Smarter Pack-Out Process
The implementation of the turnkey pack-out system marked a significant shift in how Metglas manages its heavy palletized products. What was once a labor-intensive and risk-prone process became a streamlined, automated operation that delivered measurable improvements in safety, efficiency, and cost control.
Beyond solving immediate ergonomic concerns, the system redefined how the packing line functions – transforming it into a reliable, high-performing operation with clear returns on investment.
Metglas reported:
We have a very good working relationship with AEC. From the quoting stage through the implementation stage, they’re always responsive to our needs.
AEC reduced the amount of fork truck activity in the area and eliminated the risk of back injuries on our packing line.” says Barry Cates, Project Engineer at Metglas.
With the new automated packing system, we have realized increased worker productivity and put Metglas in a position for increasing plant capacity.
Results at a glance.
- Safety First – Back injuries and ergonomic risks were virtually eliminated.
- Reduced Forklift Traffic – The pack-out area became safer and less congested.
- Boosted Productivity – Operators focused on higher-value tasks, while the packing system handled repetitive movement.
- Increased Capacity – Automated flow eliminated bottlenecks and increased throughput.
- Consistency & Reliability – The system ensured every pallet moved safely and predictably through the pack-out process.
- Labor Efficiency & ROI – Reduced manual handling lowered labor costs while increasing line efficiency.
- Operational Uptime – Integrated automation minimized downtime risks and improved long-term equipment reliability.
- Scalable Value – The system created a foundation for future expansion, ensuring the investment continues to deliver returns as production needs grow.
See the system in action!
Hytrol's Drag Chain Conveyors 
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