Automation Engineering Expertise

Dartronics expertise in automation engineering and machine manufacturing spans across various industries.  We have been successfully designing and engineering complex custom automation systems since 1996.  Please read about how we have solved some of our clients' automation challenges.

For more information on Dartronics custom automation engineering solutions, please contact us.

1 - Automated Mug Wrap Machine

The customer needed to increase speed and reduce manual labor. The original way of wrapping dye sublimation sheets around a mug was very time consuming and required a lot of manual labor but also used a recycled rubber band material that had reduced life because of heating and cooling in the ovens.

Dartronics provided an automated way to wrap 30 mugs per minute with only two people utilizing a silicon tape (throw away). The machine feeds pre-printed transfer sheets onto silicon tape and then wraps this around the mug from handle to handle very tightly and straight. We then apply a label to the bottom of the mug at the same time verifying that both the transfer sheet and label are matched. The system utilized a servo for the index table, Print & Apply Labeler, Barcode scanners, sheet feeders, Allen Bradley PLC, Red Lion Control Panel, Tape dispensers, 3 conveyors one with vacuum and one with custom pucks, pneumatics and several sensors.

2 - Custom Mounting and Digital Marking of Ice Cream Wrappers

The customer wanted to improve the marking and coding of the ice cream wrappers. The original mechanical coders did not print consistently and reliably. They also required manual change of type for product changes. We provided an HP digital printing solution. Now they can change product codes on the fly providing real time and date information. Included with the system was a operator friendly custom written software package that controls all printers with one operator interface screen.

The customer needed a way to quickly and easily remove the printing equipment from the production area so wash down could be performed. Dartronics provided a portable cart that contained Mini-Touch print head controllers, Integrated PC with touch panel with custom software, Battery Backup system, and mounting to hold 8 print heads. Each print head was removeable from the bridge without the use of tools. We provided a hand operated locking latch (not tools required) to securely hold print heads in place at the same time making it easy to remove for wash down at the end of the production run.

3 - Product Handling and Serialization of Cartons for Track and Trace

Customer was having problems with product diversion. They wanted a way to serialize every carton and track this through the distribution channel. We provided the Turn-Key solution. Not only did we mark the carton, but also the shipping cases and pallets with cradle to grave relationships. Dartronics provided the proper hardware, software, installation and training support.

Shown in picture at right is: 6' infeed conveyor that made it easy for the operator to slide flat cartons on edge from the shipping conatiner to load the machine with up to 6 minutes of product. Machine ran 200 cartons per minute. We then singulated and fed the cartons onto an ink jet base, marked the cartons with 2D serialized IR inks and human readble marks. After the carton were marked we used IR dryers to dry the ink just before cameras then read the 2D barcode and OCR the human readable marks for verification and logging.

What was also unique is that we provided product handling to take marked cartons and automatically load the in-feed of the cartoner machine. The operator did not have to handle the cartons a second time. Later in the production line we also marked the shipping cartons and pallets gathering valuable data prior to loading on the trailer or storing into the warehouse.

4 - Digital Marking sheets of Formica 4' by 8' sheets

Provided Customer digital printing system to mark sheets of Formica with product information, part nuber and logo. The sheets were later cut into smaller samples to be handed out at the stores. Dartronics provided custom mounting of the 24 print heads, custom software and integration to the customer computer system. System was sold as a bolt on top printing solution to an OEM that manufactured the product handling. Printheads were devided into two sections that could be lifted and swung out for maintenance and docking. Printer is capable of printing at speeds up to 147 feet per minute. Dryers were installed to cure the ink quickly after printing to achieve the crisp/clear marks the customer required.

5 - Product Handling and Barcode Verification of Aerosal Cans at 600 CPM.

Customer wanted 100% assurance that every can that was depalitized on the production line was identical. Dartronics provided product handling and barcode scanning system to seperate and positively identify that every can was the correct one. If a can was not verified to be correct it was removed from the line at very high speeds.

Shown in the picture is a set of drive screws to separate the cans spacing them out and supported from a parrallel set of belts to present the cans with the bottom exposed for proper scanning with SICK barcode readers. Custoer would use a hand held scanner to program the correct code to be monitored by all scanners. The first scanner to verify the code would then send a good read signal to the control panel. If a mismatch was found the can would be rejected from the production line with a high speed air cylinder. If the control panel found 3 rejects in a row the production line was stopped to investigate if all cans were inccorectly loaded. Customer purchased a second system for another production line.

6 - Top and Bottom Labeling of Snack Products

Customer needed to increase productivity and placement of the top and bottom labeling. Dartronics provided a turn-key solution to properly label products at up to 30 per minute.

Shown at right is a custom split conveyor system with seperation in middle for dual label application. Top labeler is apply only and bottom labeler is Print & Apply. Application speeds are matched to the conveyor speeds to provide proper placement of labels on product. All products were the same width but varried in height and length. The system can be adjusted quickly for product changes.

7 - High speed Print & Apply Labeling of Caulk Tubes

Customer wanted to decrease inventory of pre-printed caulk tubes. The way we accomplished this was to print & apply barcode labels specific to the product allowing them to minimize inventory carrying generic caulk tubes.

Shown at right is a Paragon Print & Apply Labeler with a high speed tamp cylinder. Afte the label is applied we can the barcode to identify the correct barcode was applied and to verify the barcode is onevery tube. Independent sensor controlled the labeler and the barcode scanner. The information to be printed comes from the production department via ethernet to the printer.