Projects
Automating Copper Handling and Sampling: EPCM’s Custom Solution for a Major Copper Producer
Mario Portilla, Automation Manager at EPCM South America
Client
One of the largest copper producers in Latin America successfully advanced its automation strategy by implementing a tailored solution at its operations in North America. With a focus on operational efficiency, repeatability, and integration with existing infrastructure, the client partnered with EPCM to develop and deploy an automated system for weighing, strapping, labeling, and sampling copper sheet bundles. The project also served as a scalable model for potential future implementation at facilities in South America and beyond.
Challenge
The primary challenge was to automate the final handling and quality sampling of copper sheets within the constraints of a brownfield site, where legacy equipment and space limitations presented significant engineering hurdles.
The manual nature of the previous process introduced variability and inefficiencies—particularly in strapping, labeling, and sample collection. Moreover, modernizing the system while preserving compatibility with existing sampling equipment required a customized, modular solution that could operate autonomously but still interface reliably with existing components.
The client required a solution that would be cost-effective, meet delivery targets, and be easily replicable in other facilities—creating long-term value through support services and spare parts availability.
Solution
EPCM developed a stand-alone automated system composed of two primary subsystems:
- A Packaging System for weighing, lifting, turning, strapping, and labeling copper sheet bundles
- An Automated Sampling Load Station, integrated with the client’s existing sampling machinery
Each subsystem was engineered to function independently but to work together seamlessly in streamlining the post-production flow. Key components included:
- Bundle weight scale for precise mass measurement
- Automated strapping machine to secure bundles with two straps
- Label printer and applicator, applying a weight ID to one of the straps
- Material-handling robot for feeding sheets into the sampling station
- Conveyor and loading tables for sample collection of the first two copper sheets
- Safety fencing, dedicated hydraulic power unit (HPU), device panels, and power distribution systems
Although on-site installation was outside the scope of this initial phase, EPCM completed a full factory acceptance test (FAT), including mechanical and electrical assembly, software debugging, safety and system validation, followed by disassembly and crating for shipment. This approach minimized installation risks and reduced commissioning time at the client’s site.
Results
The system was delivered, installed, and commissioned in alignment with budget and timeline objectives.
Once operational, the system:
- Standardized bundle handling and sampling procedures
- Improved labeling accuracy and traceability
- Reduced manual handling and enhanced operator safety
- Provided a reproducible model for deployment in other facilities, including South America
- Created a new business opportunity for spare parts and long-term support
Looking Ahead
This completed project demonstrates EPCM’s ability to deliver tailored automation solutions that integrate seamlessly into complex operational environments. From engineering and FAT to delivery and support, EPCM provides life-cycle services that maximize performance, safety, and return on investment. Contact us to learn how we can help optimize your copper operations with scalable and intelligent automation.
