Custom Automation Solutions
A Foundation in Custom Automation
Since 2009, Engenesys has designed and built custom automation equipment and integrated systems. We often provide the required custom “missing link” in production processes that include a substantial amount of standard OEM equipment. Other times, our customers ask us to combine our custom automation with other equipment to provide a complete integrated system.
We are the ideal partner for companies that have developed a new product and need custom equipment to produce it. No matter what industry we’re serving, we’re prioritizing simple, creative solutions—every project, every client, every day.
We also:
Case Study: Injection Molded Parts Cartoning System
Engenesys recently executed a large custom automation integration project for a manufacturer of injection molded parts. The customer’s goal was to automate cartoning operations downstream of four large injection molding machines. The project scope included automating the collation and loading of parts into three different carton sizes. The complete system required integration of over 250’ of new conveyor to manage the flow and delivery of cartons between a carton former, four custom carton loading stations, a carton sealing machine, a case loading station and a palletizing station.
Floor Plan
3D Model
- How does the upstream process operate and how are products being delivered to the new automation system?
Four injection molding machines each produce 48 parts per cycle. A pick robot removes the finished parts from the mold and will place them into the custom carton loading station. - Does the upstream process produce multiple products that require changeover in the automation system?
Each of the four injection molding machines produces one style of part that doesn’t change. - How are products oriented when they arrive at the infeed of the new automation system? Are there multiple orientations that require changeover?
Molded parts are delivered by a pick robot that places them consistently in the same orientation every cycle – no changeover required. - Are there any conditions affecting how the automation system handles product?
Molded product is still soft and must be gently handled throughout the process to avoid damage. - Are employees currently performing the functions that the new automation system will replace? How are they performing those steps?
Yes – employees are hand loading. - What are all the functions that the new automation system will need to perform?
The new system will receive molded parts from four molding machines, load them into cartons in the proper counts, manage the flow of empty and full cartons and deliver sealed cartons to case loading and palletizing. - What is the finished product exiting the automation system?
Finished product is sealed cartons in three different part count sizes. - Are there multiple finished product configurations that will require changeover in the automation system?
Yes — finished cartons are produced in 48, 96 and 144 count sizes. - What is the downstream process doing?
Downstream process is case loading and palletizing.
Carton Loading System
Custom Automation Projects
Engenesys has executed hundreds of custom automation projects. The projects highlighted below provide specific examples of Engenesys capabilities.
Custom Casepacker
Customer required very compact (4’ x 8’ foot print), low-cost machine with high speed and improved flexibility for integration into existing facilities. Machine was designed to receive and open cases, accept loads of bagged snack foods, close case flaps in either fan-fold or taped sequence and discharge finished cases at a rate of six cases per minute. Engenesys executed machine design and coordinated build/runoff of one machine.
Custom Pouch Cartoner
Customer required simple, low-cost cartoning machine for international markets, to interface with vertical pouch machine. Pouch cartoner was designed to receive five lanes of pouch infeed at 100 pouches/minute per lane, create pouch loads in several counts, feed and open cartons, load pouches and discharge finished cartons. Engenesys executed machine design and coordinated build/runoff of two machines.
Pallet Handling System
Customer required a pallet handling system to process large custom loaded pallets between stations in an assembly process. Full pallets were delivered to the system and shuttled to a supply station. Components were removed at the supply stations and delivered to the assembly process. Empty pallets were shuttled to a discharge station for pickup and removal.
