Press Automation: Stacking and Packaging of Stamped and Formed Parts

Efficient end-of-line automation for mass-production forming

In many companies, the manual removal, stacking, and packaging of pressed and stamped parts remains a time-consuming, error-prone, and cost-critical bottleneck. Short cycle times, repetitive manual tasks, and increasing demands on quality and workplace safety are making this process increasingly inefficient—especially in high-volume series production. This is precisely where automation comes in: The automated stacking and packaging of pressed and stamped parts is becoming a decisive factor for economical and stable production processes in stamping and forming technology.

Whether A-pillars, household appliance components, or gears—the variety of formed parts is enormous. With the Rotte AutoStack PRESS portfolio, you can automate the entire downstream pressing process, from the press outlet through precise stacking to secure packaging. Our robotic automation reduces cycle times, lowers costs, and significantly minimizes labor requirements—especially in process steps that are traditionally characterized by high manual effort.

Precise stacking and packaging of your stamped parts

The ROTTE AutoStack PRESS offers flexible solutions for the automated stacking and packaging of stamped and formed parts—our robotic automation system picks up your components directly from the press outlet and packs them into your chosen load carrier. Interlayers, specific packing patterns, or complex component nesting are just some of the many customization options available.

The ROTTE AutoStack PRESS.Base is ideal for processes in which the press already handles the stacking. In this case, the AutoStack PRESS.Base takes the stacked piles directly and places them in a single step into the desired load carrier, such as a mesh box. This reduces cycle times and ensures that the process is automated reliably and with process integrity.

The ROTTE AutoStack PRESS.Pro is used wherever parts must first be stacked before being packed into load carriers. In this configuration, stacking robots form the stacks at the transfer station, which are then packed into the designated load carriers by the packaging robot. This solution enables the handling of complex geometries as well as the nesting of parts—for example, to achieve higher packing densities within the load carrier.

Both versions are modular and can be customized. The associated intralogistics can also be automated—for example, using automated guided vehicles (AGVs). This allows full load carriers to be automatically removed and new, empty load carriers to be supplied to the system, making the entire manufacturing process more efficient and less labor-intensive.

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Our AutoStack PRESS Portfolio

ROTTE AutoStack PRESS.Base

The AutoStack PRESS.Base picks up pre-stacked components directly from the press. This requires the press to stack the components in a reliable and automation-compatible manner. The stacks are then transported via conveyor systems to the packaging robot, which packs them into mesh boxes or other load carriers. For frequently changing product types, interchangeable grippers can be used to ensure reliable gripping and packaging even with a wide variety of products.

How it works and its features:

The stacks formed by the press, which are suitable for automation, are transferred to the conveyor system
At the picking station, the packaging robot picks up the stacks and packs them into the load carrier
Two container stations ensure a cycle-time-neutral container change
Ensuring a continous production

Product example:

Robot: Fanuc M710
Stacks: Simple, all parts oriented the same way
Output: approx. 30 parts/min. (depending on stacking height)
Container: mesh box
Footprint: approx. 4 x 3 m

ROTTE AutoStack PRESS.Pro

The AutoStack PRESS.Pro picks up components individually directly at the press. Stacking is performed by industrial robots, which can efficiently handle even complex contours and nested stacking patterns. This allows for higher packing densities and the fulfillment of specific requirements. When dealing with a wide variety of products, interchangeable grippers can be used to reliably grip, stack, and package a wide range of product variants.

How it works and its features:

Parts are placed individually by the press onto the conveyor system and fed to the stacking robots
Stacking-robots form the stacks in the transfer area for the packaging robot
It is also possible to create complex nested stacks
The packaging robot removes the finished stacks and packs them into mesh boxes or other load carriers
Two container stations ensure a cycle-time-neutral container change and enable continuous production

Product example:

Robots: 2x Fanuc M10 and 1x Fanuc M710
Stacks: Custom, nested, rotated
Output: approx. 30 parts/min. (depending on stacking height)
Container: mesh box
Footprint: approx. 4 x 4 m

From the press outlet into the loading carrier—automated destacking and packaging

In stamping and forming technology, the handling of finished stamped and formed parts is a critical process step between production and further processing. Stamped or formed parts must be reliably removed after the pressing process, stacked if necessary, and packed securely into suitable load carriers before being fed into downstream processes such as assembly, coating, or shipping. In addition to pure cycle performance, damage-free handling and a continuous material flow play a central role in this process. Manual solutions quickly reach their limits when faced with rising quality requirements, high production volumes, and increasing product variety—both in terms of process reliability and cost-effectiveness. This is where our robotic automation can help by automating the stacking and packaging of your stamped and pressed parts.

Ulrich Rotte Anlagenbau & Fördertechnik GmbH therefore develops innovative, automated, and customizable solutions for stacking and packaging stamped and formed parts. With the Rotte AutoStack PRESS.Base, stacked pressed and stamped parts are efficiently, precisely, and cost-effectively guided from the press outlet to the designated load carrier. As with all Rotte solutions, the focus here is on tailor-made concepts: Each system is designed as a customer-specific solution and precisely tailored to component geometries, cycle times, material properties, and the spatial and logistical conditions on-site. Whether simple, rotationally symmetrical parts or complex geometries with high requirements—Rotte takes into account both component quality requirements and downstream processes. This results in a seamless, automated solution that optimizes the entire material flow and sustainably increases efficiency in series production.

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Reliable, efficient, customized – The Rotte AutoStack PRESS solution

In continuous shift operation, systems for handling stamped and formed parts must withstand constant high mechanical stresses as well as varying process conditions. Rotte therefore relies on robust system designs featuring durable components, precise conveyor technology, and high-performance robotic systems that can reliably handle both different part geometries and fluctuating cycle time requirements.

A particular focus is placed on short setup times and high flexibility during operation. Automatic gripper-changing systems and flexibly configurable handling strategies enable rapid adaptation to changing component variants. In the Rotte AutoStack PRESS.Pro in particular, the use of stacking robots and vision systems ensures that even complex geometries can be reliably detected, aligned, and assembled into stable stacks. Conveyor technology, robotics, and control systems are precisely tailored to the respective requirements, ensuring a continuous and stable material flow. Upon request, maintenance and service concepts can be individually tailored to your production conditions—for maximum system availability and predictable maintenance processes.

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Your Application, Our Solution – Automated Stacking and Packaging

The AutoStack PRESS from Ulrich Rotte Anlagenbau & Fördertechnik GmbH combines high-performance robotics, robust mechanics, and intelligent control systems into a solution tailored to your production needs. Our customers benefit from custom-designed layouts, clearly structured operating concepts, and the flexibility to expand their systems as product portfolios change or new expansion phases are introduced. Each system is designed to fit seamlessly into your overall concept, both technically and organizationally.

The modular architecture ensures that both high throughput and small-batch production with a wide variety of variants can be reliably managed. At the same time, automation reduces unproductive manual intervention, improves workplace safety, and increases economic efficiency—an important step toward future-proof processes in series forming technology.

«Additional solutions for the steel and metal industry

Your partner for customized automation solutions

Every production line, every material, and every target application comes with its own unique requirements. That is why Ulrich Rotte Anlagenbau & Fördertechnik GmbH develops automation solutions that are not off-the-shelf, but are specifically designed in collaboration with you. Based on a thorough analysis of your product portfolio, layout, and quality goals, we design systems that integrate seamlessly into your production—both technically and organizationally—and meet your individual, specific requirements.

From engineering and design to manufacturing, assembly, and commissioning, our team supports you throughout the entire project. Training for your employees, along with comprehensive service and maintenance support, ensures that your Rotte AutoStack PRESS operates reliably, precisely, and cost-effectively over the long term.

Contact us—we’d be happy to advise you on high-performance automation solutions for your press and stamping part production.

One Company, Many Advantages

Ulrich Rotte Anlagenbau & Fördertechnik GmbH is your specialist in custom machinery. In addition to our innovative solutions in special-purpose machinery and automation technology, you also benefit from a wide range of customer and after-sales services:

Your Advantages at a Glance:

Decades of experience in special-purpose machinery
Extensive know-how across all areas of automation technology
High expertise in the latest technologies and applications for Industry 4.0
All services from a single source—from development and design to manufacturing, assembly, commissioning, and regular on-site maintenance
Optional training of your machine operators, technicians, and supervisors at your facility
Mechanical engineering made in Germany – we design and manufacture exclusively in Germany
Personalized customer support – you will always have a qualified contact person available