Automating copper flat bar handling at Revere Copper

For over 200 years, Revere Copper has been one of the leading copper manufacturers in the United States, combining manufacturing excellence with continuous innovation. To support the modernization of its production facility in Mebane, North Carolina, Revere selected Polytec to design and implement four fully automated robotic lines dedicated to the handling of copper flat bars. The project represents a significant milestone in Revere’s digital transformation strategy, demonstrating how industrial robotics can improve productivity, process consistency, and workplace safety while preserving the quality standards that have distinguished the company for generations
Polytec developed a fully integrated automation solution specifically engineered for the unique characteristics of copper flat bars. Each robotic cell is equipped with a vacuum gripping system that guarantees safe, precise, and damage-free handling throughout the production process. Beyond material transfer, the system automatically manages short bars, separates production scraps, and optimizes material flow, ensuring continuous production with complete process control and maximum operational efficiency.
A defining element of the project was the close collaboration between Polytec engineers, Revere’s technical team, and local contractors. Before shipment, Polytec assembled and tested each robotic cell using Revere’s actual production materials during a comprehensive Factory Acceptance Test (FAT). This allowed the customer to validate system performance, optimize operating sequences, and familiarize operators with the new technology before installation. The accuracy of the engineering phase significantly reduced commissioning activities on site, enabling a smooth and rapid start-up with only minimal adjustments after installation. Following the successful installation of the first two robotic lines, Revere independently completed the installation of the remaining two systems, with Polytec providing commissioning support and final validation. This collaborative approach minimized production downtime, reduced installation costs, accelerated project execution, and strengthened the technical expertise of Revere’s internal maintenance and engineering teams.
Today, the four robotic lines operate as an integrated automation platform that improves material handling efficiency while increasing operator safety and ensuring consistent production quality.