As the global poultry farming industry advances toward higher automation and strict animal welfare standards, cage manufacturers in Europe face growing pressure to improve manufacturing precision while reducing labor costs.
Recently, DAPU successfully engineered and delivered a fully customized 2-4mm Chicken Cage Mesh Welding Line with an Automatic Mesh Flipper System for a leading poultry farming equipment producer in Italy.
This project highlights how tailormade mesh welding solutions can seamlessly bridge high-speed production with European safety and quality requirements.
The Client’s Challenge: High Labor Costs & Strict Quality Standards
Our Italian client specializes in commercial layer cage and broiler breeding systems. To meet the stringent requirements of European poultry equipment standards, they needed a specialized mesh welding solution that could address three major operational bottlenecks:
1. Wide Wire Range Precision: Smoothly processing wire diameters from 2.0mm to 4.0mm without manual tool adjustments during line changeovers.
2. Labor-Intensive Stacking: Standard welding lines require manual turning and flipping of mesh panels before stacking, leading to high labor costs and potential panel deformation.
3. Strict European Compliance: Machinery must meet high safety, electrical, and ergonomic standards (CE compliance) for continuous factory operations in Italy.
Our Tailored Solution: Automatic Mesh Welding with Integrated Flipper
To solve these challenges, our engineering team designed a dedicated poultry cage mesh welding line tailored specifically to the client’s plant layout and output goals.
Key Technical Features of the Machine:
Processing Capacity: Handles line wires and cross wires ranging from 2.0mm to 4.0mm, ideal for layer cage bottoms, side walls, and partition panels.
Automatic Mesh Flipper System (Turnover Unit): Immediately after welding and cutting, the integrated pneumatic flipper automatically rotates the welded mesh panel by 180 degrees. This allows opposing mesh structures to nest efficiently into compact stacks without human intervention.
Synchronized Control: Powered by an advanced PLC interface and servo motor feeding system, ensuring mesh opening accuracy within ±0.5mm.
European Safety Standards: Integrated protective fencing, safety light curtains, and premium European-certified electrical components.
Results & Impact for the Client
Following installation and commissioning at the client’s facility in Italy, the line achieved immediate efficiency gains:
50% Labor Reduction: Eliminating manual mesh flipping reduced the required line operators from 3 to 1.30%
Higher Output: Continuous automatic flipping and stacking enabled non-stop line operation at maximum welding speeds.
Zero Deformation: The smooth turnover mechanism protected the galvanized coating and maintained flat mesh panels for downstream cage assembly.
“The integration of the automatic flipper system made a significant difference in our daily yield. The line runs smoothly within our 2- 4 mm specifications, and the build quality fully meets European standards.”
— Technical Director, Italian Poultry Equipment Manufacturer
Upgrade Your Poultry Cage Mesh Production Today
Whether you are producing layer cages, pullet cages, or commercial breeding panels, upgrading your line with automated flipping and precise welding technology is key to staying competitive in 2026 and beyond.
At DAPU, we design and manufacture custom welded wire mesh machinery tailored to your exact wire gauge, panel size, and automation needs.
