Turn-Key Solutions and Rollon: Engineered a robotic solution for an automated AS/RS storage system

Founded in 2003, Turn-Key Solutions (TKS) has become a prominent system integrator specializing in robotic automation and industrial automation solutions. Scott Etzel, who took full ownership six years ago, has since led the company through a period of rapid “hockey stick” growth. He has spearheaded expanding its operations across the United States, Mexico, Brazil, and Germany. And the results have been impressive, with a year-over-year growth rate of 25%.

TKS provides comprehensive, 360-degree service to its customers, fostering long-term relationships built on trust and reliability. Turn-Key Solutions’ approach enables them to manage mechanical engineering, electrical engineering, robot programming, HMI, machining, painting, welding, and assembly — all in-house. This comprehensive service offering has set them apart in a competitive industry.

The Challenge

One of TKS’ recent projects involved designing an automated storage and retrieval system for a customer. The application required two robots to process parts. To add complexity, they needed to move products vertically up to 30 feet and horizontally over 60 feet. The situation demanded long strokes and high dynamic performance in a continuous operation. Additionally, the system needed to accommodate unit loads of up to 136 kg. The project demanded reliable equipment that could endure such a heavy-duty schedule. But more critically, it also required precise accuracy at 1.5 mm and speed.

Faced with this challenge, Turn-Key Solutions had two options for their industrial automation solutions. They could either build a custom solution in-house or purchase a pre-existing product that would meet their needs. After carefully evaluating the options, the choice was clear. They recognized the complexity of the task and the need for a reliable, high-performance actuator.

The solution: Rollon® ROBOT 220 Actuators

Turn-Key Solutions partnered with Rollon to find the right solution. The ROBOT 220 belt-driven actuator was ideally suited to meet the project’s demands. Its ability to handle long-stroke, high-dynamic applications was ideal. Moreover, its load capacity suitable for the 136 kg pallets ensured it could meet operational needs.

When taken as a whole, the system’s capabilities and level of unflappable reliability were undeniable. They ensured it would be a cornerstone of the client’s warehouse automation technology stack. Its stress-ready optimization made it the ideal choice for this application.

Rollon’s ROBOT 220 actuator proved ideal for the vertical lift. This is thanks, in part, to its ability to meet the required performance under continuous, high-frequency usage.

Rollon’s ROBOT belt-driven actuator

The collaboration between TurnKey Solutions and Rollon has been ongoing for four years. Rollon’s products have played a critical role in helping TKS provide high-quality, reliable robotic automation solutions to their customers.

“Our core business is robotic automation, covering areas like material handling, assembly, welding systems, and machine tending. Essentially, if it involves robotics, we provide a solution. We offer fully integrated, turn-key solutions to our customers. Some come to us with a specific problem, and we collaborate to find the best answer. Others know exactly what they need, and we work to deliver that while adding our own innovative touch to stand out from the competition. This is where using a product like Rollon gives us an edge — the quality and proven history of their solutions make a real difference”, says Etzel.

Results and benefits

The ROBOT 220 actuators delivered on their promise. They enabled Turn-Key Solutions to successfully provide an automated storage and retrieval system (AS/RS systems). This ensured smooth, dynamic part movement while meeting the application’s demanding performance requirements.

A wide range of improvements were noted. Everything from speed to load capacity to accuracy were optimized. As expected, the implementation of right-sized automated storage and retrieval systems pushed the client into a new level of capability. But the benefits didn’t stop there.

The partnership with Rollon extends beyond just products: it is also about support. For Etzel, service and support are in fact crucial.

The construction phase of the automated storage and retrieval system (AS/RS systems), equipped with Rollon’s ROBOT actuators.

© Turn-Key Solutions

“We’ve expanded our offerings significantly and pride ourselves on providing a complete, 360-degree service. Our team stays on-site and doesn’t leave until everything is running perfectly, and the customer is completely satisfied. Our relationships are built on trust —we have clients that we’ve worked with for over 20 years.

Once we partner with a company, we maintain that connection, growing with them over time. Our business thrives on organic growth, which is why offering excellent support and services is critical. We have the expertise internally, and the people who have solved similar challenges before are still here to do it again,” explains Etzel.

“That’s where Rollon stands out — they provide the support we need, going the extra mile. In fact, it’s not just about us: it’s about our suppliers supporting us so we can, in turn, support our customers. This kind of partnership is crucial, and it’s something I really appreciate about the entire Rollon team.”

“Many of our customers now specifically request Rollon products. These are major clients, and that speaks volumes about the quality of Rollon’s solutions and the exceptional service their team delivers”, concludes Etzel.

Conclusion

Turn-Key Solutions’ success in delivering comprehensive, turn-key robotic automation solutions is fueled by strategic relationships. The partnership with Rollon is the latest and strongest example yet. The use of Rollon’s ROBOT 220 actuators helped overcome complex automation challenges. They ensured precision and performance while providing the service and support necessary for long-term success.

As TKS continues to expand, Rollon remains a trusted partner. New projects sit on the horizon that will feature Rollon products. This steadfast partnership will only serve to further strengthen TKS’ ability to deliver top tier robotic automation solutions.

For more information on Rollon’s linear motion solutions, connect with Rollon application engineers in your area or region.