WSA USA Full Plant Automation SolutionsEnd-to-End Integration for Corrugated Box Plant Performance

Total Plant Automation. One Integrated System.

WSA USA delivers complete full plant automation systems engineered to connect every stage of corrugating and box converting operations—from material handling and production to finished goods and warehouse storage.

Rather than isolated equipment, WSA USA full plant automation solutions bring together conveyors, robotic systems, load handling technologies, and advanced controls to create fully integrated, high-performance corrugated manufacturing environments.

Core Automation Technologies

Conveyor Systems

The Backbone of Continuous Material Flow

WSA USA conveyor systems form the foundation of plant automation, linking corrugators, converting machines, and downstream operations into a synchronized material flow.

Capabilities include:

• High-capacity transport of bundles, sheets, and finished loads
• Accumulation and buffering to maintain uninterrupted production
• Custom layouts engineered for plant-specific throughput and space constraints
• Integration with upstream and downstream automation systems

These systems eliminate manual transport and ensure stable, predictable production flow across the facility.

Robotic Top Pad Insertion with Labeling Integration

Automated Load Protection and Identification

WSA USA integrates robotic systems for top pad insertion combined with automated labeling, ensuring finished loads are both protected and traceable as they move downstream.
Internal project planning ensures robotic systems are integrated as part of broader automation phases, including commissioning and production support for full system deployment.

Key advantages:

• Consistent top sheet placement for load coverage
• Integrated load tag or label application for tracking
• Reduced labor and improved ergonomic safety
• Scalable automation aligned with plant production growth

Strapper Systems with Integrated Controls

Secured, Consistent Load Containment

WSA USA strapper systems are engineered with fully integrated controls to ensure reliable, repeatable load securing within the automated process.
Internal system documentation highlights strapper interface integration and control system modifications as part of broader automation strategies

Key capabilities:

• Automated load strapping integrated into conveyor flow
• Centralized controls for consistent performance
• Adaptability for different load sizes and configurations

Increased throughput with minimal manual intervention

Load Tiering Systems

Precision Load Building for Downstream Efficiency

Load tiering devices organize finished goods units into double stacked units exactly as they will be
loaded into either the trailer or the warehouse eliminating another time consuming manual step by
the shipping area fork lift driver and allows for automatic trailer loading by AVG’s..

Core benefits:

• Accurate, repeatable load configuration
• Improved downstream handling efficiency
• Reduced product damage and handling variability
• Seamless transition to truck loading or storage warehouse

Pallet Inserting Solutions

WSA manufactures several different automatic pallet inserter systems depending on the application.
Pallet Inserters automatically place finished goods units onto a selected pallet size and have the
added ability to place two units on one pallet or two units on two pallets when integrated with our
Load tiering devices. The WSA Pallet Inserter eliminates the need for a fork lift driver in the shipping
area having to place units manually onto pallets thereby eliminating another time consuming step.

Core benefits:

• Accurate and highly efficient
• Improved downstream handling efficiency
• Reduced product damage and handling variability

Vertical Storage & Handling Solutions

Optimized Space Utilization and Inventory Flow

WSA USA provides vertical storage solutions designed to maximize facility footprint while
maintaining efficient access to materials and finished goods.
These systems are positioned as part of broader automation strategies, including vertical rack and
storage system expansion within plant automation categories

Key advantages:

• High-density storage for raw materials, WIP and finished goods
• Automated or semi-automated retrieval systems
• Improved inventory organization and visibility
• Scalable design for future plant expansion
• Smaller footprint versus traditional WIP solutions

Robotic Palletizing Systems

Automated End-of-Line Efficiency

WSA USA robotic palletizers deliver high-speed, precise stacking of finished loads, completing the
automation cycle from production to warehouse readiness.

Key features:

• Flexible configuration for multiple product types and patterns
• Integration with upstream tiering and strapping systems
• Reduced labor dependency and improved consistency
• Enhanced throughput and end use load quality
• Designed for todays latest high speed FFG and RDC converting lines

Engineered as a Unified Automation Platform

WSA USA takes a systems-first approach, ensuring all equipment operates as part of a
coordinated automation strategy.

Project execution includes:

• Full system integration of conveyors, robotics, and controls
• Structured commissioning phases for progressive automation enablement
• Alignment between mechanical equipment and plant-wide control architecture
• On-site production support to optimize performance post installation

This approach ensures reliable start-up, predictable performance, and continuous improvement over
time.

Measurable Business Impact

WSA USA full plant automation solutions deliver tangible results:

• Increased production throughput and line efficiency
• Significant labor reduction across handling and finishing processes
• Improved uptime through consistent, automated material flow
• Enhanced safety through reduced manual interaction
• Scalable infrastructure to support future growth

WSA USA full plant automation solutions bring together conveyors, robotic systems, load
handling technologies, and advanced controls to create fully integrated, high-performance
corrugated manufacturing environments.
The result is a connected, intelligent plant—optimized for efficiency, reliability, and long-term
competitiveness.