Line 05
Cut-to-Length Lines (CTL)
Coil into flat, precisely cut sheets — levelling, servo length control and careful stacking, configured around the material and the order book.
- 30,000 - 300,000 t/yr
- Thickness 0.15 - 16 mm
- Cut length tolerance within ±0.3 mm
- Stop-cut / flying shear / rotary shear
From coil to sheet
The cut-to-length line turns coil into flat, accurately cut sheets. It is the last processing step before fabrication: sheets leave the line for construction sites, machinery works, appliance assembly and stamping plants.
Because the line sits close to the customer, it changes what a service centre can sell — cut-to-order sheets instead of coil, with length, flatness and surface agreed against the order.
Dimensional control
Servo feed and shear logic hold cut length while the line is running.
Flatness after levelling
Multi-roll levelling removes coil set and residual stress before shearing.
Surface protection
Air-float stacking and optional film or paper interleaving protect coated material.
Mixed materials
Carbon, galvanized, prepainted, stainless and aluminium can share one line.
Where the sheets go
| Industry | Products |
|---|---|
| Construction | Floor decking, roofing sheets, wall panels, C and Z purlin blanks, connection plates |
| Machinery | Equipment base plates, frame plates, flange blanks, structural components |
| Automotive | Frame rails, floor pans, door inner blanks, body structural parts |
| Appliances | Refrigerator side panel blanks, washer top blanks, microwave cavity sheets |
| Hardware | Shelving, tool chest bottoms, electrical cabinet doors |
| Transportation | Container side panels, truck bed panels, ship interior panels |
| Service centres | Custom-cut sheet distribution to downstream fabricators |
Cutting, stacking and capacity options
Three choices define the line: how the strip is cut, how the sheets are stacked, and how fast the line runs. They are selected together against the material mix and the order book.
Cutting method
| Type | Principle | Best for | Cutting rate |
|---|---|---|---|
| Stop-cut | Strip stops momentarily for the shear, then resumes | Thick gauge from 1.0 mm, high precision, small to medium batches | 15 - 40 cuts/min |
| Flying shear | Strip runs continuously; the shear travels with the strip | Thin gauge up to 2.0 mm, high volume | 40 - 80 cuts/min |
| Rotary shear | Drum-mounted blades cut at line speed | Ultra-thin gauge up to 0.5 mm, maximum throughput | 80 - 120 cuts/min |
Stacking method
| Method | Principle | Best for | Strength |
|---|---|---|---|
| Air-float stacker | Air cushions carry each sheet to a gentle landing | Galvanized, prepainted, stainless, aluminium | Surface kept free of scratches |
| Magnetic stacker | Electromagnets lift and release the sheets | Thick carbon steel from 1.5 mm | Neat, tight stacks |
| Mechanical stacker | Back stop and lifting platform align the sheets | General carbon steel | Simple and cost-effective |
| Vacuum suction stacker | Vacuum pads pick and place each sheet | Thin, scratch-sensitive material | Gentle handling, lower speed |
Capacity tiers
| Tier | Line speed | Annual capacity | Application |
|---|---|---|---|
| Economy | up to 30 m/min | 30,000 - 80,000 t/yr | Small processors, multi-product, short runs |
| Standard | 30 - 60 m/min | 80,000 - 150,000 t/yr | Regular service centres with a stable order book |
| High speed | 60 - 120 m/min | 150,000 - 300,000 t/yr | Large service centres, high-volume production |
Process sequence and specifications
The sequence runs from uncoiling to a strapped stack, with levelling and length measurement placed before the shear so accuracy is set before the cut.
Process sequence
| Stage | Operation |
|---|---|
| Coil handling | Overhead crane to expanding-mandrel uncoiler |
| Entry | Pinch leveler, then crop shear for head and tail |
| Looping (optional) | Entry looper for continuous coil change |
| Levelling | Multi-roll precision leveler |
| Measurement | Encoder or measuring roll sets the cut length |
| Shearing | Stop-cut, flying shear or rotary shear |
| Transport | Belt conveyor moves sheets to the stacker |
| Stacking | Air-float, magnetic, mechanical or vacuum stacker |
| Packaging | Strapping and transfer to finished goods |
Technical specifications
| Parameter | Range | Notes |
|---|---|---|
| Annual capacity | 30,000 / 50,000 / 80,000 / 100,000 / 150,000 / 200,000 / 300,000 t | Standard tiers; custom available |
| Strip thickness | 0.15 - 2.0 mm thin / 0.5 - 6.0 mm medium / 3.0 - 16.0 mm heavy | Sets the leveler and shear specification |
| Strip width | 300 - 1,250 mm standard, up to 1,600 or 2,000 mm | Wider lines need larger equipment |
| Cut length | 500 - 6,000 mm standard, up to 12,000 mm | Longer lengths need a longer line |
| Cut length tolerance | within ± 0.3 mm with servo feed; ± 0.5 mm with encoder | Stop-cut holds tighter accuracy than flying shear |
| Diagonal tolerance | ± 0.15 - ± 0.3 mm/m | Affects sheet squareness |
| Flatness after levelling | 1.0 - 2.0 mm/m² | Result of multi-roll levelling |
| Maximum line speed | 30 / 60 / 80 / 100 / 120 m/min | Configuration dependent |
| Stack height | 500 - 800 mm, thickness dependent | Auto-descending platform |
| Installed power | approx. 150 - 800 kW | Capacity and configuration dependent |
| Approx. footprint | 600 - 1,500 m² | Includes raw material and finished goods storage |
Precision levelling
Levelling decides the quality of everything that follows. Coiled strip carries curvature and residual stress, and only thorough levelling gives the flatness and dimensional stability a fabricator expects.
- Leveler rolls in GCr15, 9Cr2Mo or alloy tool steel, hardness HRC 58 - 62
- Backup rolls support the work rolls and hold assembly rigidity
- Roll gap adjusted electrically or hydraulically for each thickness
- Quick roll change design to limit downtime
| Leveler | Rolls | Thickness range | Flatness | Recommended for |
|---|---|---|---|---|
| 5-roll or 7-roll | 5 - 7 | 2.0 - 16 mm heavy | Moderate | Economy configuration |
| 11-roll | 11 | 0.5 - 6.0 mm | Good | Standard configuration |
| 17-roll | 17 | 0.15 - 3.0 mm thin | Excellent | Thin gauge with high surface requirement |
| 21-roll | 21 | 0.15 - 2.0 mm | Superior | Precision strip, stainless, aluminium |
Length measurement and shearing
Length accuracy comes from the measuring system and the shear acting together. Servo feed closes the loop on cut length, while the shear type sets the achievable throughput.
Length measurement
| System | Principle | Accuracy | Application |
|---|---|---|---|
| Encoder | Measuring roll rotation generates a pulse signal | ± 0.5 mm | Standard configuration |
| Servo feed | Servo motor drives the feed rolls in closed loop | ± 0.3 mm | High precision, thin gauge |
| Vision (optional) | Vision sensor detects strip marks | ± 0.2 mm | Special specifications |
Shear types
| Shear | Thickness | Cutting rate | Characteristics |
|---|---|---|---|
| Hydraulic stop-cut | 0.5 - 16 mm | 15 - 40 cuts/min | High cutting force and clean edge |
| Mechanical flying shear (swing) | 0.3 - 3.0 mm | 40 - 70 cuts/min | High speed for volume production |
| Mechanical flying shear (drum) | 0.15 - 2.0 mm | 70 - 120 cuts/min | High speed for very thin gauge |
| Disc flying shear (narrow strip) | 0.2 - 2.0 mm, narrow | 60 - 100 cuts/min | For strip width up to 800 mm |
Blades are SKD-11, Cr12MoV or high-speed steel. Blade life depends on gauge, material and cut length rather than a fixed figure.
Stacking, conveying and automation
How sheets land decides whether the surface survives. Stacking is therefore specified with the material, not left as a late choice between suppliers.
Stacking and packaging equipment
| Equipment | Function | Detail |
|---|---|---|
| Belt conveyor or roller table | Transports sheets from shear to stacker | Speed matched, no scratching |
| Air-float stacker | Air cushions each sheet to a gentle landing | For coated, stainless and aluminium |
| Magnetic stacker | Electromagnets lift and release sheets | For thick carbon steel |
| Auto-descending platform | Lowers as the stack builds | Stack height up to 500 - 800 mm |
| Strapping machine | Circumferential and longitudinal strapping | Automatic tensioning |
Automation
| Level | Function | Key components |
|---|---|---|
| Line PLC | Speed synchronisation, length calculation, shear logic, stacker coordination | Platform agreed with the plant standard |
| HMI | Recipe management, parameter setting, monitoring and diagnostics | Touch screen, multi-language |
| Servo and VFD drives | Speed control for leveler, conveyor and stacker | Independent drives |
| Length and count system | Real-time cut length and piece count | High-resolution encoder with high-speed counter |
Materials and finished products
One line can handle several materials, but the leveler roll surface, tension control and stacking method are set for the mix you actually run.
Suitable materials
| Material | Representative grades | Thickness | Requirement |
|---|---|---|---|
| Cold-rolled steel | ASTM A1008 / EN DC01 / JIS SPCC | 0.15 - 2.5 mm | Surface protection |
| Hot-rolled steel | ASTM A1011 / EN S235 / JIS SPHC | 0.5 - 16 mm | Strong levelling for heavy gauge |
| Galvanized (GI / GL) | ASTM A653 / A792 / EN 10346 | 0.2 - 3.0 mm | Air-float stacking to protect the coating |
| Prepainted (CCL) | Colour coated coil | 0.2 - 1.2 mm | Film protection and air-float stacking |
| Stainless steel | ASTM 304 / 430 / 201 / 316 | 0.2 - 6.0 mm | Dedicated leveler roll surface |
| Aluminium alloy | ASTM 1060 / 3003 / 5052 / 6061 | 0.15 - 4.0 mm | Lightweight material, special tension control |
| Silicon steel | Non-oriented / grain-oriented | 0.15 - 0.65 mm | Precision levelling, scratch prevention |
Finished product range
| Product | Length | Width | Thickness | Application |
|---|---|---|---|---|
| Cut-to-length heavy plate | 2,000 - 12,000 mm | 600 - 2,000 mm | 3.0 - 16 mm | Steel structures, machinery bases |
| Cut-to-length sheet | 500 - 6,000 mm | 300 - 1,600 mm | 0.15 - 3.0 mm | Appliances, automotive, hardware |
| Film-laminated sheet | Custom | Custom | 0.15 - 1.2 mm | Appliance and decorative panels |
| Roofing and wall panel | Custom | 300 - 1,000 mm | 0.4 - 1.5 mm | Building envelopes |
Standard scope of supply
The line is supplied as one sequence from entry to packaging. Leveller, shear and control system can also be supplied as a set where part of the line already exists.
| Module | Included equipment | Engineering detail |
|---|---|---|
| Entry section | Uncoiler, pinch leveler, hydraulic crop shear, optional entry looper | Precise expansion for varied coil diameters |
| Levelling section | Multi-roll precision leveler with backup rolls and gap adjustment | Precision-machined rolls for flatness |
| Shearing section | Stop-cut or flying shear, servo feed, length encoder | Accuracy with long blade life |
| Conveying section | Belt conveyor or roller table, acceleration separator | Sheet spacing without surface damage |
| Stacking section | Air-float, magnetic or mechanical stacker with lifting platform | Neat stacks, surface protected |
| Packaging section | Automatic strapping machine, weighing system | Secure strapping |
| Electrical and automation | PLC, HMI, drives, length control system | Platform per plant standard |
| Auxiliary systems | Hydraulic station, pneumatic system, lubrication | Complete supply from one source |
Supply options
| Mode | Scope | Best for |
|---|---|---|
| Turnkey | Process design, full equipment, installation supervision, commissioning and training | New service centre investors |
| Core equipment | Leveller, shear and control system | Clients with existing equipment or local fabrication |
| Upgrade or retrofit | Diagnostics, leveler replacement, shear upgrade, automation retrofit | Existing lines with accuracy or efficiency issues |
| Single machine | Leveler, shear or stacker as a standalone unit | Replacing one section of an existing line |
Spare parts and retrofit
Leveler rolls, shear blades and measuring rolls are the parts that wear first. Stocking and retrofit support continue after handover.
- Cut length, piece count, speed and downtime monitored in real time
- Blade wear prediction and blade change scheduling
- Mobile app for production reports, line status and alerts
Typical spare parts
| Part | Application | Detail |
|---|---|---|
| Leveler rolls | Precision leveler | Complete sets, ground to specification |
| Shear blades | Shear | Upper and lower, SKD-11 or high-speed steel |
| Blade clearance parts | Shear | Screw or wedge adjustment mechanism |
| Measuring rolls | Length measurement | Supplied with matched encoder |
| Conveyor belts | Conveying section | Oil-resistant or anti-static |
| Air-float fan impellers | Air-float stacker | Dynamically balanced |
| Hydraulic cylinder seals | Hydraulic system | Full sets |
| Strapping feed and tension wheels | Packaging section | Wear-resistant material |
Retrofit options
| Retrofit | Scope | Typical driver |
|---|---|---|
| Leveler upgrade | More rolls or a precision leveler | Flatness below standard |
| Shear accuracy upgrade | Stop-cut to flying shear, or servo feed | Accuracy or throughput |
| Stacker upgrade | Mechanical to air-float or magnetic | Surface complaints |
| Automation upgrade | HMI, recipes and data logging | Long changeovers, operator dependence |
| Film or paper interleaving | Film applicator or paper layer | High surface requirement |
| Capacity upgrade | Higher line speed with upgraded drives | Order growth |
| Remote monitoring | Data acquisition, cloud platform and mobile app | Multi-site management |
Configuration inputs
What we need to specify this line
- 01Material types and thickness range
- 02Cut length range and tolerance
- 03Capacity target and shift pattern
- 04Stacking method and surface protection
Questions
Questions we hear on this line
Stop-cut, flying shear or rotary shear?
Stop-cut gives the highest accuracy on thicker material, flying shear keeps the line running for thin gauge and volume, and rotary shear suits very thin strip where throughput matters most.
Can one line handle several materials?
Yes, provided the leveler roll surface, tension control and stacking method suit the full mix. That is why the material list is reviewed before the line arrangement is fixed.
How is flatness achieved?
Through multi-roll levelling before the shear, with roll count selected against gauge. Flatness is measured during commissioning against the value agreed in the specification.
Related terms
What engineers search for on this line
- cut-to-length line
- CTL line
- sheet shearing line
- cut to length machine
- steel sheet cutting line
- leveling and shearing line
- precision cut to length
Other lines
Sections planned in the same scope
Pickling Lines (PPL & CPL)
Turnkey push-pull and continuous pickling lines for hot-rolled strip, covering scale breaking, acid pickling, rinsing, fume treatment and acid regeneration.
Reversing Cold Rolling Mills (CRM & TCRM)
Turnkey single-stand and tandem reversing cold rolling mills for carbon, silicon, stainless and HSLA strip, with hydraulic gauge and automatic flatness control.
Continuous Hot-Dip Galvanizing Line
Turnkey continuous hot-dip galvanizing lines for GI, 55% Al-Zn and Al-Zn-Mg coatings, from cleaning and annealing through the zinc pot, skin-pass and chemical treatment.
Planning a new line or an upgrade?
Send the product mix and target capacity, and we will review the configuration.