Hydraulic Coil Handler Safely Moves and Stores 5-Ton Coils

At Star 1 Products, innovation often starts with a simple customer request. The Coil Handler machine — one of the company’s newest developments — is a perfect example of how the company listens, solves problems, and creates solutions tailored to the unique challenges of roll forming shops. When the first customer approached them about designing a machine that could efficiently store and handle coils within their limited space, they saw an opportunity to build something truly useful.

The Birth of the Coil Handler

Star 1 Products’ Nelson Miller said the first Coil Handler was designed to fit a shop with low ceilings and limited space. The customer needed a way to store coils in a shop with low ceiling space while still being able to access them efficiently. They had seen a single-row coil handler in use and wanted something similar but larger. So Star 1 built its first unit from the ground up, figuring out the design as they went. The first unit was configured to six coils wide and thirteen coils long, so it could accommodate 78 coils. From there, the company refined the system and developed additional single-row models inspired by the original concept.

Ray Wagler once again played a key role in the foundation of this design. Many of the products built at Star 1—such as wide forks, the film applicator, and the long folder—have roots in Ray’s original shop projects at Elite Metal. He wasn’t interested in manufacturing at scale, but his ideas set the stage for innovations that the team at Star 1 could refine and bring to the market.

Refinements and Enhancements

The first large-scale Coil Handler, with space for 78 coils, was completed in May 2020. It featured an operator riding along for easy maneuverability. After two years of real-world use, they went back in 2022 to upgrade the design, replacing the original I-beams with stronger ones to improve durability. The machine has proven itself to be a reliable, efficient solution for their customers.

Today, the company continues to push the limits. They’ve built single-row systems as long as 200 feet—allowing shops to maximize their storage capacity. Most of their standard units are around 100 feet long, which works well for a variety of coil types, including textured and printed colors. With the increasing variety of coil finishes available—camo, wood, crinkle colors—shops need more storage than ever. Nelson says some now stock 60+ different coil options, making efficient, organized storage solutions essential.

Solving Key Challenges 

Before the Coil Handler, many roll forming shops relied on forklifts for coil handling. While functional, this approach had its downsides:

• Availability Issues: Forklifts are often in use elsewhere, causing delays in coil changes.

• Coil Damage: Forklifts increase the risk of damaging coil edges.

• Inefficiency: Changing coils with a forklift takes longer, slowing down production.

With the Coil Handler, these issues are eliminated. The dedicated machine ensures coils are always ready for quick changes, reducing downtime and increasing efficiency. Since operators ride along with the coil, they have better visibility, reducing the risk of damage. Customers who have adopted this system in Michigan have reported significant improvements in speed and organization, making it easier to keep track of inventory and access the right coils when needed.

The Coil Handling Process

In most cases, coils move from the Coil Handler to a decoiler and then into a roll former. They’ve designed the system to work seamlessly with mobile decoilers, allowing for a smooth transition:

1. The Coil Handler grabs a coil and moves it to the decoiler.

2. The decoiler, mounted on wheels, moves into position.

3. The coil is secured, and the decoiler moves back in line for the next step in processing.

Built to Last

The Coil Handler is constructed with a heavy-duty tube-frame design. It features a hydraulic cylinder with a five-ton lifting capacity, making it capable of handling 10,000-pound coils. Powered by hydraulics, the system is designed for longevity and durability.

Installation and Foundation Requirements

They’ve installed Coil Handlers on 6” concrete slabs, but they also adapt to custom requirements. In one case, a customer wanted the ability to drive a forklift across the tracks. Since their building was still under construction, they built a recessed trench in the concrete to house the Coil Handler tracks, ensuring smooth forklift access without interference.

A Niche Solution for a Growing Market

At Star 1, they develop solutions that meet the specific needs of roll forming shops. While electronic and computerized options are available in the market, the Coil Handler is designed to provide hands-on control—making it an excellent fit for Plain Communities and other businesses that prioritize safety, accuracy, and efficiency without the need for more complex technology.

They follow a simple but effective approach: Build a prototype, test it in real-world conditions, refine the design, and then expand production. This process has served the manufacturer and the roll-forming industry well, not just with the Coil Handler, but also with other products like the Felt Applicator. 

Looking Ahead

The demand for efficient coil storage and handling solutions continues to grow. With lead times currently at six to eight months, the team is staying busy fulfilling orders. As metal roofing and siding products evolve, they expect even greater interest in solutions that streamline workflow and maximize shop space.

With the Coil Handler, Star 1 has created a tool that doesn’t just store coils—it transforms the way roll forming shops operate. They look forward to helping more customers improve their efficiency, organization, and productivity.  RF