sheet metal rack vertical

At CFS Industrial Solutions , we engineer die rack systems that redefine heavy-duty storage for automotive and precision manufacturing industries. This case study explores how we designed a pneumatic die racking solution for a Tier-1 automotive supplier in Michigan, addressing critical challenges in mold storage efficiency and workspace optimization.

Client Challenge: High-Capacity Storage for Stamping Dies

The client required die rack systems capable of storing injection molds weighing up to 4,400 lbs (2,000 kg) while minimizing floor space. Their existing setup caused workflow delays due to manual handling risks and limited accessibility, with molds often requiring 15+ minutes for retrieval.

CFS’s Custom Die Racking Solution

Pneumatic Three-Column Die Rack System

Engineered for automotive stamping dies and large-scale injection molds:

●  Dimensions : 9.5’ (L) x 2’ (W) x 9.5’ (H)

●  Capacity : 4,400 lbs (Layer 1) / 2,200 lbs (Layers 2-4)

●  Key Innovations : CFS SE63 Pneumatic Actuators : Smooth 24” drawer extension with 360° access

○ Modular steel frame supporting 36–40 storage positions

○ ASTM Q235B cold-rolled steel construction with 0.08” reinforced panels

○ OSHA-compliant safety interlocks to prevent accidental closure

This die racking system reduced mold retrieval time by 50% through one-touch pneumatic controls, critical for high-mix production schedules.

Technical Specifications: Industrial-Grade Engineering

Component

CFS Die Rack Standard

Structural Frame

3” C-channel steel (ASTM A36)

Drawer Slides

4-rail system with 0.2” hardened tracks

Coating

80μm epoxy-polyester hybrid (RAL 5010)

Safety Features

Dual locking pins, overload sensors

Tested at CFS’s Ohio R&D Center , the system exceeds ANSI MH31.2-2023 standards through 10,000-cycle stress testing

Why CFS Delivers Superior Die Racking Performance

1.  Automotive-Focused Design : Drawer dimensions (35”x24”) align with SAE J1227 mold plate standards to prevent tool damage.

2.  Space Optimization : 40-position configuration stores 120+ mid-size dies in 200 sq.ft, reducing floor space costs by 45%.

3.  Ergonomic Operation : Pneumatic controls eliminate manual lifting – operators manage 4,400 lb molds with <5 lbs of force.

4.  Lifecycle Support : 12-year warranty with IoT-enabled predictive maintenance alerts for actuators and bearings.

Post-implementation metrics showed:

● 60% reduction in mold handling incidents

● $85,000 annual savings in labor costs

● 33% faster production line changeovers

Industry Insights: Optimizing Die Management

For manufacturers evaluating die rack systems :

● Conduct load audits using CFS’s proprietary 3D scanning tools to map tool weights/dimensions

● Prioritize vertical density with multi-tier die racking over horizontal expansion

● Integrate RFID tracking with CFS’s IoT-ready racks for real-time inventory management