The Smart Material Handler (SMH) is Kongsberg's intelligent sheet-handling solution for Kongsberg cutting tables. It is designed to guide both the loading and offloading process so that idle time between jobs is minimised and operators are free to focus on higher-value tasks.

How It Works

The SMH introduces a structured workflow: while one sheet is being cut, the operator stages the next sheet in the loading area. As soon as the current job finishes, the new sheet moves into position immediately — eliminating the manual gap that traditionally exists between jobs.

Simultaneously, the offload area provides a dedicated zone for collecting finished work, ensuring the cutting surface is cleared quickly and cleanly. This staging and offloading cycle reduces downtime between runs and minimises the risk of material damage.

Key Features

• Operator-assisted registration for accurate sheet placement every time
• Optional Under Side Camera (USC) for print-side-down job registration
• Alignment bracket maintains sheets parallel to conveyor movement
• Rollfeeder ready — switch between sheet and roll production quickly
• Compatible with Kongsberg C and Ultimate configurations in 2×, 4×, and 6× setups

Market Applications

The SMH is ideal for operations producing sign & display graphics, corrugated packaging, and folding carton applications where sheet variety is high and job changeovers are frequent.

Operator Benefits

• Shorter learning curve — simple, guided operation for new staff
• Fewer material handling errors and sheet damage incidents
• Consistent sheet registration reduces reprints and waste
• Operator can complete other tasks during the cutting cycle

The Kongsberg Feeder & Stacker is an advanced, modular board-handling solution that provides a seamless pallet-to-pallet workflow. It is designed to significantly increase productivity by removing the manual intervention required for loading and unloading at each end of the cutting table.

How It Works

Boards are loaded onto the feeder pallet. The feeder automatically picks boards from the stack and positions them precisely on the cutting table. Once cut, the stacker collects finished pieces and organises them onto the output pallet — all without operator handling mid-cycle.

This continuous loop means the cutting table runs at near-maximum capacity, with interruptions only for pallet exchanges — which can be planned around production schedules.

Core Advantages

• Modular design — feeder and stacker can be used together or independently
• Short run optimisation — ideal for high-volume, varied-job environments
• Reduced material waste — consistent, precise board positioning every cycle
• No additional labour required — no extra headcount needed to operate
• Easy integration — designed to work with existing Kongsberg table setups

Who Benefits Most

The Feeder & Stacker delivers the greatest impact in environments running high-volume, short-run corrugated, folding carton, or rigid board jobs — especially where shift costs and material damage have been key pain points.

Comparison: Manual vs. Automated

• Manual handling: operator loads and offloads each sheet, table idles between jobs
• With Feeder & Stacker: continuous cycle, operator manages exceptions only, near-zero idle time

The Robotic Material Handler represents the highest level of automation available in the Kongsberg portfolio. It enables fully unattended or near-unattended production by using industrial robotics to load sheets directly from a pallet and unload finished pieces — all with exceptional precision and no intermediate handling.

Target Markets

This solution is purpose-built for digital finishing companies in:

• Sign & display production (rigid and flexible substrates)
• Folding carton manufacturing
• Corrugated packaging operations

How It Works

The robot arm loads directly from the incoming pallet — using the same process pallets your materials arrived on — and unloads completed work to the output pallet. There are no scissor lifts, no work tables, and no intermediate staging zones required. The system handles corrugated board, paper-core boards and a range of plastics.

Key Benefits

• True unattended production — run overnight or across multiple shifts without supervision
• High precision at all times — consistent placement eliminates registration errors
• No intermediate handling — direct pallet-to-table-to-pallet cycle
• Material flexibility — handles corrugated, paper-core boards and plastics
• Reduces operator fatigue — eliminates repetitive physical handling entirely

Labour & Cost Impact

By shifting repetitive material handling to the robot, skilled operators are freed to focus on quality control, job setup, and production planning. Across a multi-shift operation, this can represent a significant reduction in direct labour costs and a substantial increase in overall equipment effectiveness (OEE).

Beyond sheet-handling solutions, Kongsberg offers a set of advanced automation tools that target specific workflow challenges — from dual-zone operation and roll-based soft signage production to take-up and waste collection. Together, these solutions complete the automation ecosystem.

MultiZone Production

Larger Kongsberg tables (such as the Ultimate series) support MultiZone finishing — splitting the table into two independent work zones that operate simultaneously. While the table cuts in one zone, an operator prepares the next sheet in the other, resulting in near-continuous production.

• Maximises utilisation of large-format tables
• Ideal for mixed-size jobs that do not fill the full table surface
• No additional hardware required — enabled through table configuration and software

Motorized Roll Feeder

For high-volume soft signage and flexible material jobs, the Motorized Roll Feeder provides active material feed for the Kongsberg C64, eliminating inaccurate cuts caused by wrinkles, stretch, or imperfectly wound rolls.

• Market-leading precision on tensile and stretch-prone materials
• Supports continuous production from first cut to end of roll
• Designed for wide-format soft signage applications

Take-Up Unit

The Take-Up Unit enables roll-to-roll workflows for digitally printed flexible materials. Easy to install on any Kongsberg table with a conveyor feed, it collects finished output on a roll and manages waste cleanly.

• Simple installation and removal — can be moved away when not needed
• Supports finishing of digitally printed roll jobs end-to-end

The Full Picture: Choosing the Right Combination

Selecting the right automation combination depends on your material types, job mix, and volume:

• Sheet-heavy, short runs: Feeder & Stacker
• Varied jobs, guided operation: Smart Material Handler
• Unattended multi-shift production: Robotic Material Handler
• Large table, mixed jobs: MultiZone Production
• Soft signage & roll media: Motorized Roll Feeder + Take-Up Unit