Small Pack Collator

In the world of high-velocity roof tile production, some of the most elegant mechanical concepts were born before digital technology existed to fully control them. At WELSCH, we have taken a visionary sleeping idea from the late 1990s and, utilizing over 25 years of specialized manufacturing data, completely re-engineered it for the future.

Between 2003 and the 2020s, our company team was repeatedly tasked by major factories to redesign and manufacture critical sub-assemblies for legacy systems. This gave us an unprecedented X-ray view of the original design's inherent weak points. Following the global industrial shifts of the early 2020s, our team returned to a core technical challenge: How to achieve a 150 TPM packaging cadence without sacrificing the surface integrity of the tile.

The WELSCH small pack collator achieves this through a series of specialized zones designed to preserve surface quality at relentless speeds:

Kinetic Intake: It begins with our dual feeding round-belt conveyors, which catch the tiles and create the precise gaps required for high-speed synchronization. From here, the tiles enter the heart of the machine: a double-sided paternoster elevator equipped with protective L-shaped guide rails.

High-Velocity Lift: The small pack collator utilizes a sophisticated dual-circuit architecture to manage high-speed vertical transitions. This system features two independently rotating double-chain conveyors integrated into a single vertical frame. While the first circuit is occupied with the discharge and return loop, the second integrated conveying system is already at the intake collecting the next batch.

Soft-Touch Accumulation: Once at the apex, a driven pusher system transfers the tiles into our proprietary fan-rail stacking. Unlike horizontal sliders that can scuff fresh acrylic, our fan-rails index the tiles vertically, placing them on top of each other with surgical care to eliminate friction and edge-chipping.

Small Pack Strap Banding & Rotation: After the small pack (variable from 4 to 8 tiles) is secured by our integrated strap banding stations, it meets our second magic feature: the synchronized rotation arm system. This unit performs a precise more than 90-degree axial turn, reorienting the bundle for optimal structural stability.

Unitizing: Finally, these bundles are handed over to the collection chain conveyor. This staging track accumulates the small packs into high-density 40-tile rows, creating a perfectly aligned roof tile bar ready for the final gantry pickup.

Whether operating at our 120 TPM standard or our 150 TPM high-end configuration, the WELSCH small pack collator proves that high volume does not have to mean high damage. We have replaced the mechanical disasters of the 1990s with a state-of-the-art electronic heart.

Safe-Touch Handling: Small packs of 4, 5, or 8 tiles are formed vertically to prevent edge-chipping and surface scuffing. Ergonomic Packs: Optimized for the roofer's convenience, allowing for easy lifting and individual laying on the roof. Sustainable Logistics: By maximizing bundle stability, we reduce the need for excessive plastic dividers and hot-melt waste.

We didn't just look at an old drawing; we lived the evolution of this machine for more than twenty years as an engineering center and specialized components manufacturer. In 2023, we decided it was time to move beyond maintenance and into perfection. The WELSCH small pack collator is the definitive result: a 150 TPM master class in vertical mechatronics that finally delivers on the visionary promise of the 1990s. We haven't just updated the technology; we have fulfilled its destiny.