PROJECTS
Lines we have built.
Twenty representative projects. Real scope, real equipment, real numbers — anonymized where customer NDAs require.
20 projects
Food & Beverage•2025Dairy bottling line retrofit — 18% throughput, 62% fewer rejects
Replaced a 1998-era controls stack with modern PLC + vision while keeping the existing filler and capper steel.
+18%Throughput-62%Reject rate11 wkProject lead time
Food & Beverage•2025Robotic palletizing cell — 2 shifts of manual stacking eliminated
Greenfield palletizing cell at end-of-line, sized for 60 cases per minute across 12 SKUs with quick-change tooling.
2Shifts of manual stacking replaced60 cpmCases per minute16 moProjected payback
Food & Beverage•2024AI vision defect detection — escape rate cut from 0.6% to 0.04%
Replaced rule-based blob analysis with a deep-learning model for label crease, low-fill, and cap-tilt defects on PET bottles.
0.04%Customer escape rate+9%OEE points gained<200 msPer-bottle decision time
Warehousing & Logistics•2025Goods-to-person AGV fleet — 320 robots, 3.2× pick rate
Designed and commissioned a 320-AGV goods-to-person system across 240,000 sq ft, replacing two-level mezzanine pick.
320AGVs deployed3.2×Lines per hour per associate12 wkFull ramp
Metal Fabrication•2024Stamping press robot tending — zero recordables, 22% more strokes
Three identical FANUC R-2000iC cells tending 400-ton mechanical presses, eliminating hand-feeding at the die.
0Recordable injuries+22%Strokes per hour3 cellsScope
Metal Fabrication•2025Twin-arm structural welding cell — 2.4× deposition rate to AWS D1.1
Two coordinated welding arms on a single 5-axis positioner for medium structural weldments up to 1,800 lb.
2.4×Deposition rate vs manualAWS D1.1Weld standard14 wkDelivery from PO
Packaging•2024Personal-care packaging line — 8 SKUs, sub-3-minute changeover
Greenfield secondary packaging with case erector, top-load packer, and hot-melt sealer designed around fast SKU changeover.
30 cpmCases per minute8 SKUsActive SKUs<3 minChangeover time
Packaging•2025DTC fulfillment bagger line — 1,800 orders/hr at 99.7% accuracy
Pick-to-bag fulfillment cell with vision-verified SKU match, auto-bagger, and print-and-apply at sustained 1,800 oph.
1,800 ophOrders per hour-58%Labor vs baseline99.7%Order accuracy
Consumer Goods•2024Appliance final-assembly conveyor — 180 jph, 16 stations
Final-assembly conveyor with lift tables, ergonomic tooling, and andon system for a major appliance OEM.
180 jphJobs per hour16 stationsAssembly stations+11%First-time quality
Automotive•2024Tier-1 EGR cooler assembly line — 60 ppm, full traceability
Cell-based assembly with leak test, servo press, laser marker, and per-unit data capture for IATF 16949 compliance.
60 ppmRateIATF 16949Standard100%Traceability
Automotive•2025EV battery tray welding cell — aluminum 5083, 0.2 mm flatness
Robot MIG cell for aluminum EV battery trays with vision-guided seam start and a post-weld dimensional gate.
Al 5083Material0.2 mmFlatness120 secCycle time
Building Products•2024Cabinet shop modernization — lot size of 1, +45% throughput
Nest-based CNC routing, edgebanding, and robotic hardware insertion turned a batch shop into a lot-size-of-1 operation.
+45%Throughput-30%Scrap rate1 of 1Economic lot size
Building Products•2025Modular home wall-panel line — 1 panel every 9 minutes
Framing jig with auto-nailing gantry and a sheathing gantry for wood-framed wall panels.
1 panel / 9 minPer panel3 crews → 1Crew per houseOSB + 2xScope
Pharma & Medical•2024Pharma blister inspection — 21 CFR Part 11, zero escapes since
Cavity-fill and color verification on blister packs with full electronic-record audit trail.
21 CFR 11Compliance0 escapesSince launch320 bpmRate
Pharma & Medical•2025Class II medical device assembly — ISO 8 cell, 100% UDI
Cleanroom assembly cell with Stäubli stericlean robot, UV laser marker, and per-unit UDI capture.
ISO 8Cleanroom class100% UDITraceability0.95 CpkProcess capability
Electronics•2024PCB selective conformal coating — ±0.25 mm edge accuracy, 100% AOI
In-line selective coater with UV cure and downstream AOI for industrial-control board assemblies.
± 0.25 mmEdge accuracy100% AOIVerification75 boards/hrRate
Food & Beverage•2025Frozen ASRS — 9,200 pallet positions at −25 °C
Pallet shuttle ASRS in a –25 °C freezer with cold-rated drives, lubricants, and condensation control.
−25 °COperating temp9,200Pallet positions−40%Energy per pallet-day
Specialty Agriculture•2024Specialty fruit grading — 5 grades, 12 t/h, 70% less labor
Multi-spectrum optical sorter with air-knife rejects and tray-pack robotics for premium specialty fruit.
5 gradesGrade classes12 t/hThroughput−70%Labor vs baseline
Building Products•2024Glass annealing lehr controls retrofit — 18% less gas, +6% yield
Burner control and thermal-profile retrofit on a specialty glass annealing lehr.
−18%Natural gas usage+6%Annealed yield5 wkCutover outage
Consumer Goods•2024Housewares paint line — 120 jph at ΔE < 1.2
Robotic paint booth with cure-oven exit color verification for high-mix housewares product.
120 jphRate+22% TEPaint transfer efficiencyΔE < 1.2Color match
- Dairy bottling line retrofit — 18% throughput, 62% fewer rejects
- Robotic palletizing cell — 2 shifts of manual stacking eliminated
- AI vision defect detection — escape rate cut from 0.6% to 0.04%
- Goods-to-person AGV fleet — 320 robots, 3.2× pick rate
- Stamping press robot tending — zero recordables, 22% more strokes
- Twin-arm structural welding cell — 2.4× deposition rate to AWS D1.1
- Personal-care packaging line — 8 SKUs, sub-3-minute changeover
- DTC fulfillment bagger line — 1,800 orders/hr at 99.7% accuracy
- Appliance final-assembly conveyor — 180 jph, 16 stations
- Tier-1 EGR cooler assembly line — 60 ppm, full traceability
- EV battery tray welding cell — aluminum 5083, 0.2 mm flatness
- Cabinet shop modernization — lot size of 1, +45% throughput
- Modular home wall-panel line — 1 panel every 9 minutes
- Pharma blister inspection — 21 CFR Part 11, zero escapes since
- Class II medical device assembly — ISO 8 cell, 100% UDI
- PCB selective conformal coating — ±0.25 mm edge accuracy, 100% AOI
- Frozen ASRS — 9,200 pallet positions at −25 °C
- Specialty fruit grading — 5 grades, 12 t/h, 70% less labor
- Glass annealing lehr controls retrofit — 18% less gas, +6% yield
- Housewares paint line — 120 jph at ΔE < 1.2