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Smart Unloading System

Model 1: WF-ST2.2Model 2: WF-ST3.0
SMART UNLOADING SYSTEM · Vacuum-Cup Gantry Manipulator

An automatic slab stacker installed on the discharge side of the saw: cut slabs are pushed off, picked up by vacuum cups, transferred, stacked and counted automatically, at a constant 1 slab/min, 24 hours a day, with 1 operator for 5 machines.

Smart Unloading System at work on site
1 slab/minConstant unloading cycle
THE PROBLEM

The faster you cut, the harder the stacking:
unloading is the most painful step in a stone plant

Manual stacking today
2–3 workers/shift
Bending, lifting and stacking: heavy, repetitive labor
Output lost across shifts
Later shifts run slower
Fatigue eats directly into output, and night shifts are even harder to staff
Safety risk
Crush · strain
Slabs from tens of kilograms up to 600 kg, all moved by hand
Counting disputes
Counted by hand
Count sheets kept by hand; every miscount becomes an argument

The Smart Unloading System hands this most exhausting, most dangerous and most error-prone step to a manipulator: workers never touch the slab, the cycle is constant, counting is automatic, working in sync with the saw to complete the whole unloading process, for granite, marble, limestone and engineered stone alike.

WORKING FLOW

A Slab's Fully Automatic Journey

Five actions run in a loop with no human intervention, and they are also the working standard checked item by item at acceptance.

1Smart sawing

The saw cuts to depth, leaving a precise margin

Working with the saw, slabs are cut with the depth controlled precisely at about 1/4 of slab thickness where separation is needed, leaving a break path for mechanical separation without cutting through or chipping the face.

2Automatic push-off

Pneumatic push-off · gently parts the slab along the kerf

The push-off mechanism gently separates the pieces along the pre-cut kerf, replacing manual prying with even force and controlled direction that protects edges and faces.

3Vacuum pick-up

Vacuum-cup gantry manipulator pick-up

The gantry manipulator positions itself automatically and the vacuum cups adjust suction to the surface, lifting each slab smoothly; granite, marble, limestone and engineered stone surfaces are all gripped reliably.

4Transfer stacking

Automatic transfer · stacking onto a stack or pallet

The manipulator transfers the slab to the stacking position and stacks it neatly by the set rule; stacking height and position are adjustable in the PLC, supporting wooden racks, pallets and direct stacking.

5Counting & count sheet

Automatic counting · count sheet generated in step

Each stacked slab is counted automatically and the count sheet is generated per batch: how many slabs cut today, how many per stack, no more hand counting when reconciling with customers.

SYSTEM COMPOSITION

Four Systems, Each With Its Job

Vacuum-cup gantry manipulator

A rigid gantry structure with a long stroke covering the saw's discharge area and the stacking area; a multi-cup layout adapts to the slab face, with adjustable suction and smooth motion.

Pneumatic push-off mechanism

Gently parts slabs along the pre-cut kerf, with force and stroke controlled by the PLC to suit different thicknesses, eliminating the edge damage caused by manual prying.

PLC control system

Linked to the saw's signals to coordinate the cycle automatically; parameters (slab length, stacking layers, cycle) are adjustable on the panel, with fault self-diagnosis and on-screen prompts.

Automatic counting & count sheet system

Every unloading count becomes a ledger entry and count sheets are generated automatically; data can be exported to a cloud dashboard / AI stock-in sheet (optional), keeping accounts crystal clear.

SPECIFICATIONS

Specifications: Two Models, Chosen by Slab Length

Model 1: WF-ST2.2 suits regular large-slab cutting; Model 2: WF-ST3.0 suits 3-meter-class long slabs and large formats.

Note: capacity is estimated under standard conditions (regular granite slabs, full-width stacking); specific parameters are subject to the contract's technical agreement.
Parameter Model 1: WF-ST2.2 For regular slabs Model 2: WF-ST3.0 For extra-long slabs
Slab length≤ 2.2 m≤ 3.0 m
Single-slab weight≤ 300 kg≤ 600 kg
Installed power18 kW22 kW
Machine heightapprox. 2.5 mapprox. 2.5 m
Footprintapprox. 6.0 × 4.3 mapprox. 6.8 × 5.1 m
Unloading cycleConstant 1 slab/minConstant 1 slab/min
Daily output (standard conditions)approx. 1,600 m²/dayapprox. 2,600 m²/day
Continuous operation24-hour continuous production24-hour continuous production
Staffing1 operator for 5 machines1 operator for 5 machines
ControlPLC auto-cycle · linked to the sawPLC auto-cycle · linked to the saw
HandlingVacuum-cup gantry manipulator + pneumatic push-off
MaterialsGranite / marble / limestone / engineered stone

Site requirements: three-phase power and compressed air; a clear workshop height of ≥3 m is generally sufficient (machine height about 2.5 m). Before the engineer's visit, please provide workshop floor dimensions, door opening size, saw model and a photo of the discharge side.

MANUAL VS UNLOADING SYSTEM

Unloading: Manual vs Smart Unloading System

Item Manual stacking Smart Unloading System
Stacking methodBending and lifting, hard physical workAutomatic stacking by vacuum-cup manipulator
CycleFluctuates with fatigue, slower as the shift goes onConstant 1 slab/min, 24h non-stop
Labor input2–3 workers per shift for stacking1 operator supervises 5 machines at once
Injury riskHotspot for crush and strain injuriesWorkers never touch the slab, zero lifting in operation
Damage controlKnocks are unavoidable, breakage disputes are commonDamage-free cups + smooth motion, damage is traceable
Counting & reconciliationManual counting, easy to miss or miscountAutomatic counting, count sheets generated automatically
Long-term costWages rise every year, and hiring is hardOne-off investment, low electricity cost, no labor-cost growth for years

Based on typical labor costs in stone regions, the equipment usually pays for itself in about a year through labor savings (indicative; an engineer can prepare a free calculation for your plant).

FAQ

FAQ

Integration hinges on the discharge-side layout and signal interface. Most bridge saws and CNC saws can be linked by adding sensors or signal wiring; if the saw has no external signal at all, the system can run semi-automatically at a fixed cycle. Confirmed by the engineer on site.
No. The cup array is assigned automatically to the slab size with adjustable suction, and the holding force is calculated with a safe margin; flat granite, marble, limestone and engineered stone are all gripped reliably. We recommend sending slab samples or photos before selection so the engineer can confirm the cup configuration.
The equipment cycles automatically to its program, with no per-slab operation. On an abnormality the PLC alarms and stops in a safe position; the operator only patrols periodically, handles alarms and changes stacking pallets. With several machines in a row, one patrol round covers them all.
The equipment itself supports 24-hour automatic operation. Whether a night shift can be unstaffed depends on the workshop: whether the saw feeds slabs automatically and whether there is enough stacking space. We suggest starting with one operator on patrol, then evaluating unstaffed or lightly staffed periods once it runs smoothly.
Standard configurations are scheduled for production in about 30–45 days (depending on the order queue); on-site installation and commissioning usually takes 3–7 days including operator training. The schedule is confirmed in writing before signing so your start-up plan is not affected.

Find the Model That Fits Your Workshop

Send your slab specifications and workshop photos; an engineer confirms the model and issues a quote the same day.

Get a Quote
Hotline4008-119-722