Inser Metal · Automation for metal structure manufacturers From the coil to the truck. One single line.
We automate the profile’s whole journey so that every step runs at the same pace, from end to end.
EuroBLECH 2026 Hannover · 20–23 October · Hall 27, stand L165
Book a meeting at the stand What we are showing-
Think better automation
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Wider vision
An isolated solution can solve a task.
A global vision can improve your whole operation.
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Inser Metal
From the coil to the truck.
- 01 Feeding
- 02 Joining
- 03 Hanging
- 04 Unhanging
- 05 Packaging
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01
Inser Metal · From the coil to the truck
Feeding
Profiles are picked and fed into the line.
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02
Inser Metal · From the coil to the truck
Joining
Welding, riveting or bolting.
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03
Inser Metal · From the coil to the truck
Hanging
Hung on the paint conveyor, in motion.
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04
Inser Metal · From the coil to the truck
Unhanging
Unhung from the conveyor, in motion.
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05
Inser Metal · From the coil to the truck
Packaging
Stacked, strapped, wrapped. Ready to ship.
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Emulation and simulation · in-house software
See your line running before you buy it.
- Before you invest — validate performance before installing anything.
- Every day after — anticipate bottlenecks and optimize the sequence.
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Our method
- ThinkUnderstand the system
- ShapeDefine the solution
- BuildExecute it reliably
- OptimizeMaintain it and evolve it
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Inser Robótica
- 1987automating since then
- +1,000projects delivered
- +600customers
- 17countries
Designed and built in Europe.
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Think better automation
- Wider vision
- Right decisions
- Higher efficiency
- 1987automating since then
- +1,000projects delivered
- +600customers
- 17countries
From the coil to the truck
The whole plant,
from the coil to the truck.
The coil waits on its cradle, which is what keeps it from rolling. The overhead crane picks it up by the eye —not with a forklift— and the coil car carries it along the rail to the decoiler: there the mandrel holds it from the inside and the strip comes out flat towards the straightener.
The profile comes out straight and cut to length: roll formed from steel coil, or extruded in aluminium. The two lines live side by side because the starting material is not always the same.
The component is joined to the beam. The same table architecture works for welding, riveting or bolting, depending on the part.
The robot follows the advance of the overhead conveyor and hangs without stopping the line. On the other side of the tunnel, unhanging does the same in reverse.
The beams are grouped and move on as a bundle. Strapping makes it stable and wrapping closes it, with the label somewhere visible and no strap covering it.
The bundle is stored long-side-loaded —its long side facing the rack— which is what lets it come straight out without manoeuvring. Cantilever racking, with no upright in front, and a stacker crane guided by floor and roof rails.
The plant floor sits 1.20 m above the yard, which is what keeps the dock leveller almost flat so the bundle rolls out instead of climbing. The bumpers mark where to pull in, and the chock keeps the truck from moving while it is loaded.
Inside stage 02 · Production
Five zones. One single line.
So far, the whole plant. From here on we go inside production, which is where the metal structure line lives: five zones, each with a different challenge. Pick yours: what we solve, how, and with what.
01 Feeding
The challenge
Getting the profile to the joining tables from different sources and formats, in exactly the right position and without anyone lifting it. And pulling out the faulty profile before it reaches the weld.
How we solve it
We adapt the infeed to the way the profile arrives: straight from the roll former, from a four-post structure or from strapped bundles.
With what
- Direct integration with the roll former and in-line dimensional control
- Six-axis robot with laser positioning to pick profile by profile
- Cartesian destacker with permanent magnets to load layer by layer
- Automatic rejection of any profile that is out of spec
02 Joining
The challenge
Bringing in new products without reprogramming, compensating for deviations in the part, and keeping every joint —welded, riveted or bolted— to the same quality, whoever is on shift.
How we solve it
A configurable joining area, from one table to six or more, to weld, rivet or bolt depending on the part, sized for today’s capacity without closing off tomorrow’s.
With what
- Welding, riveting or bolting within the same table architecture
- Our own path-generation software: the program for each product in minutes, from the 2D profile and the 3D component
- Automatic joint location, with no laser seam tracking
- Automatic torch correction, with no manual recalibration
- Component feeding with up to an hour and a half of autonomy per load
- Quality control that can be built in: pores and holes from 0.5 mm
03 Hanging
The challenge
Feeding the paint line at the conveyor’s pace, with no gaps, no stops and nobody hanging parts by hand.
How we solve it
In a fixed position, by decoupling a section of the conveyor, or on the move: the robot follows the advance and hangs without stopping the line.
With what
- Conveyor tracking and synchronisation with its speed
- Decouplable section with controlled working positions
- The rest of the line keeps running while parts are hung
04 Unhanging
The challenge
Taking the painted part off at the line’s pace and moving it on to its next destination before it piles up.
How we solve it
Unhanging in a fixed position or synchronised on the move, with the transfer solved towards buffering, conveying or packaging.
With what
- Robotic handling synchronised with the paint line
- Conveying and transfer to the next process
- Integration with the next process
05 Packaging
The challenge
Clearing the output without slowing the pace, building stable bundles and keeping forklifts out of the cell.
How we solve it
Stacking, labelling, strapping, wrapping and transport to storage or to the loading dock, designed around where the product is going: part by part, in batches, or decoupling processes to move it to another area or another plant. And when the bundle does not go straight onto the truck, we also automate the infeed and outfeed of the store for long and heavy loads, so the end of the line does not turn into a forklift yard.
With what
- Stacking onto fixtures, chain conveyor or four-post structure
- Wrapping, strapping and labelling the bundle
- Traceability for every bundle that leaves
- Removal by complete batches, with fewer forklift entries
- Automated infeed and outfeed of the bundle store, for long and heavy loads
Which of the five is setting your pace?
If you already know which one it is, that is enough to start. The project does not need to be defined yet.
Tell us which oneSound familiar?
Six questions. Yes or no. Thirty seconds.
At the end we tell you which part of the line we would start with.
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1 / 6
Is anyone carrying profiles by hand between the roll former and the joining tables?
Automatic feeding from the roll former, from bundles or from a four-post structure: the profile reaches the tables without anyone lifting it.
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2 / 6
Does every new product mean reprogramming the robot?
Path-generation software: the program for each product in minutes, with no recalibration.
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3 / 6
Does weld quality depend on who is at the station that day?
Automatic seam finding and torch correction, with in-line quality control where the process calls for it.
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4 / 6
Does the paint line stop, or run with gaps, because of hanging or unhanging?
Hanging and unhanging on the move, synchronised with the conveyor.
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5 / 6
Do forklifts come into the cell to take the product out?
Batch packaging —stacking, strapping, labelling and wrapping— with fewer forklifts coming into the cell.
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6 / 6
Are you weighing up an investment and unsure whether it is the right size?
Emulation of the complete line with your throughput figures, before you buy anything.
Your result
This is where we would start.
- 01Feeding
- 02Joining
- 03Hanging
- 04Unhanging
- 05Packaging
- +Emulation
If none of this is happening to you, the interesting conversation is a different one: how much capacity you will need in two years, and whether today’s line can carry it. That is answered by emulating.
What other manufacturers answer
Take it with you. Scan and take your result with you, along with the whole page to read at your own pace.
The simulation · with in-house software
Start with one module. And watch it run before you buy it.
What grows is the joining area: from one table to six, without rebuilding what comes before or after it. And before the investment is committed we emulate it with your throughput, your products and your cycle times, to see which station is surplus and which one will fall short. Try it here on an example line: change the tables, the feeding lines and the joining cycle, and watch where the material piles up.
One joining table.
Line output
0 parts/h
Bottleneck
—
- Feeding0 %
- Joining0 %
- Packaging0 %
Your production times
- s / part
- s / table
- s / part
These three figures come from your product and your plant, not from the machine. Put your own in and see which station falls short. A real emulation is built with your products, your changeovers and your cycle times: tell us about your case.
And this is what it actually looks like
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EmulationThe emulator The emulator
A pallet racking plant with real orders: every product travels through buffers, tables and hanging, with the times in plain sight.
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3D simulationThe plant, in 3D The plant, in 3D
A new beam plant running in simulation before it is built.
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Welding pathsThe paths The paths
Beam family, component, length and angle: the weld is simulated and the program goes to the cell.
Before you invest
To design the line
- Test configurations with real production data
- Define the architecture your plant needs
- Validate performance before installing anything
- Neither oversized nor undersized
And every day after that
To produce better
- Simulate a week with many different products
- Decide the optimal production sequence
- Minimise changeover times
- Anticipate bottlenecks and raise output
Path-generation software · also ours
A new product, programmed in minutes
- Profile2D data
- Component3D geometry
- Programgenerated on its own
Fine tuning is done in the cell itself, and changing product does not force a recalibration.
What can be measured
Figures measured on our own lines.
0.5 mm
up to 1.5 h
1 → 6
Minutes
75 %
4.8/5
How the decision gets judged
OEE, OTIF and ROI: the three figures you will have to defend.
You close the number with your own costs. We give you the data it comes from: the emulation hands you the real throughput, the stations that are surplus or short, and the stoppages that build up.
OEE
Overall Equipment Effectiveness
What the line actually produces against what it would produce if it never stopped and everything came out right first time. Three factors multiply together: one of them drops and the whole figure drops.
What we give you: The emulation gives you the three separately, station by station, before the line exists.
OTIF
On Time In Full
An order only counts if it arrives on the agreed day with everything in it. It is the figure your customer looks at, and the first one to suffer when the plant runs at its limit.
What we give you: It can be tested beforehand: we put a rush order or a product change into the emulation and see what holds.
ROI
Return On Investment
It is calculated with your costs and your prices, not with ours. That is why we do not promise it: what we provide is the part of the calculation that can be checked.
What we give you: Parts per hour, stations needed, how busy each one is and expected downtime. With that, the number is yours to make and yours to defend.
All three are worked out from the same data. That is why the emulation comes before the investment is committed, not after the line is built.
From simulation to reality
Filmed on site, with the line running.
What you just emulated, built and running. Clips of our own lines and of the technology inside them.
Complete line, from profile to exit
Profile feeding, joining with several robots, conveying and exit of the finished part.
- On site
- Technology
References
We work in 17 countries
And there are metal lines of ours running in Spain, the United Kingdom, Germany and the United States, four of the 17 countries we work in. All of them designed in Mungia.
- Mungia, where it is designed
- Country where we work
- Area with a metal line of ours
Steel structure manufacturers already working with us.
Plus more than 600 customers in 17 countries, across every sector.
Different products, the same bottleneck
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01
Racking and industrial storage
Hundreds of beam and upright lengths, and a changeover that eats the shift.
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02
Scaffolding and temporary structures
Heavy parts and demanding welds: where ergonomics shows up first.
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03
Structures for construction
Roofing, trusses and nodes. High variety, short production runs.
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04
Cable management
Roll forming, punching, and packaging that multiplies the product range.
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05
Structures for renewables
Trackers, frames and towers. High volume and deadlines with no slack.
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06
Road safety
Guardrails, barriers and posts. Heavy forming and large batches.
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07
Telecommunications
Towers, masts and frames. Long, awkward assemblies.
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08
Security and fire doors
Resistance welding, hardware and hanging, all on the same part.
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09
Light metal furniture
Short runs, many finishes and assembly-heavy work.
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10
Fire protection
Threaded pipe and hanging for paint, with traceability on every part.
Who answers when the line stops?
Our own technical service. Three out of four incidents are resolved without leaving Inser, through a remote connection, and when someone has to travel, they travel. Wherever the plant is.
- 1 Remote support An immediate answer, wherever you are.
- 2 On-site intervention For when someone has to be in front of the machine.
- 3 IoT platform Maintenance and monitoring driven by data, not by hunches.
- 4 Training and handover So your team does not depend on ours.
Brochure
Racking Production Lines
The whole brochure, with nothing to download. Open it the way you open paper.
Drag the page, or use the arrow keys.
Brochure
Efficient Scaffold Manufacturing
The whole brochure, with nothing to download. Open it the way you open paper.
Drag the page, or use the arrow keys.
Brochure
Fire Protection Piping
The whole brochure, with nothing to download. Open it the way you open paper.
Drag the page, or use the arrow keys.
We answer for the line once it is producing, too.
Proven experience
Since 1987, with more than 1,000 projects delivered and maintained.
One line, one point of contact
From roll forming to shipping: one supplier, one phone number.
Emulation before building
The line runs with your profiles and your throughput before it is built.
Modular and scalable
Start with one module and grow without rebuilding what is already there.
Repeatable quality
The same weld on the first beam of the shift and on the last.
Our own IoT platform
Live data from the whole line through our industrial internet (IoT) platform.
One single line, from the coil to the truck.
Performance is decided across the whole flow: how the line is planned, how it is controlled and how it grows with you.
Nine answers before the first meeting.
Which part of the process do you automate in a metal structure plant?
From the coil through to the bundle going onto the truck: roll forming, feeding, joining —welding, riveting or bolting—, hanging and unhanging on the paint line, and packaging. You can also automate one part only and leave the rest ready for later.
Does it work for pallet racking, shelving and scaffolding manufacturers?
Yes, and the list does not end there. We have lines running for shelving and pallet racking beams, for profile and component, for riveting scaffold bases and for pipe prefabrication. If your part is a profile that gets formed, joined, painted and shipped, the line is closer to yours than it looks.
What does packaging at the end of the line include?
Stacking, labelling, strapping, wrapping and transport to storage or to the loading dock. Like every other module, it can be added on its own or alongside the rest.
How long does it take to program a new product?
Minutes. The path-generation software builds the program from the 2D data of the profile and the 3D geometry of the component, and the fine tuning is done in the cell itself.
Do you need laser seam tracking to weld structures?
No. Automatic seam finding adapts the path to where the part actually is, and handles product changes without recalibration.
Can it be automated in stages?
Yes. The lines are modular: each module works on its own, combined, or added later, without redoing what is already installed.
How do you know the investment is the right size before committing to it?
By emulating the line before building it, with real throughput, reach and cycle times. It is how you see whether a station is surplus, or whether another will fall short in two years.
Where do you have metal structure lines running?
There are lines of ours running in Spain, the United Kingdom, Germany and the United States, four of the 17 countries we work in. All of them are designed at our headquarters in Mungia (Bizkaia), Spain.
Who is Inser Robótica?
An industrial automation and robotics engineering company founded in 1987 in Mungia (Bizkaia), Spain, with more than 1,000 projects delivered, more than 600 customers and work in 17 countries. It designs, builds and commissions its own lines, and maintains them through its technical service division, Inser Services.
The latest we have published on metal structures.
August 2026
Inser Robótica at EuroBLECH 2026: transforming the metal structure manufacturing flow in Spanish
Is your production moving slower than you need? See at EuroBLECH 2026 how the metal structure manufacturing flow can be transformed.
July 2019
Welding path programming away from the robot: a new product in minutes in Spanish
It generates the welding program for each beam from the 3D of the profile and the 2D of the connector, without going through the robot. Product…
January 2018
Manufacturing beams for pallet racking. in Spanish
Inser Robótica designs and commissions solutions for manufacturing beams for pallet racking. We have robotic automation for every stage: – Welding of beams and connectors. –…
Think better automation
- Wider vision Look at the whole plant before touching a machine. What slows a line down is almost never where it hurts.
- Right decisions Decide with data: emulating, measuring and putting the numbers on the table before buying anything.
- Higher efficiency More uptime, better quality and processes that hold. Efficiency follows from them.
Tell us which part of the line is holding you back and we will tell you where we would start.
Knowing which profile you make, at what rate and where the material sits waiting is enough for us to tell you whether this makes sense for you, and what it would take to know for certain.
Carry on from your phone. Scan and take the whole page with you. And if you would like us to call, leave your details below.
