Case Studies

Proof in Practice. Purpose in Performance. We don't speak of what we can do. We show what we've done. Every project we take on is a living example of our philosophy in action— where systems work not just with precision, but with conscience.

High-Speed Delta Robot Pick & Place Automation

Development of a 4-axis Delta Robot for high-speed pick-and-place operations, integrating Omron NX-IP Motion Control and Cognex Vision for precision and speed. The system was designed to handle dynamic conveyor tracking with extreme accuracy.

Our Solution:

The kinematic algorithms were developed from scratch, optimized for motion efficiency and synchronized with real-time vision inputs. Using Cognex Vision for part detection and Omron NX-IP for motion control, the robot achieved seamless coordination between the conveyor and end effector. An Omron HMI provided live control, diagnostics, and recipe management.

Technologies Used:

  • Controller: Omron NX-IP Motion Controller
  • Vision System: Cognex
  • HMI: Omron
  • Axes: 4-Axis Delta Configuration

Outcome:

  • Achieved 100 picks per minute with precise repeatability
  • Fully synchronized vision-motion control
  • Modular, scalable control architecture
  • Enhanced operator interface and process visibility

Fully Automated Bottle Line – Filling, Labelling & Packaging

Design and integration of a fully automated bottle packaging line comprising rotary filling and capping, BOPP labelling, warmer and cooling tunnels, shrink wrapping, and palletizing — achieving production speeds of up to 500 bottles per minute.

Our Solution:

The line integrates each stage through a centralized PLC and HMI-based control system, ensuring seamless synchronization and real-time monitoring. The rotary filler and capper manage high-speed throughput, followed by precise BOPP labelling. Bottles are stabilized through warmer and cooling tunnels, then shrink-wrapped in multi-pack configurations before final palletizing. Recipe control and automated changeovers enable flexibility across product SKUs.

Technologies Used:

  • Rotary filling & capping system
  • BOPP labeller
  • Warmer & cooling tunnels
  • Shrink-wrap (FuzePack-type) machine
  • Palletizing system
  • Centralized PLC + HMI control

Outcome:

  • Achieved up to 500 BPM with synchronized automation
  • Fully integrated end-to-end packaging process
  • Reduced manual handling and downtime
  • Consistent packaging quality and higher line efficiency

Automated Chemical Reactor Control System with Redundancy

Automation of a chemical reactor system using Wago PLCs with Ethernet/IP and Modbus TCP/IP for precise process control, redundancy, and SCADA-based supervision.

Our Solution:

A dual-PLC redundant setup ensured continuous operation while managing recipe-based dosing, temperature, and pressure control. The Zenon SCADA handled visualization, alarms, and data logging. QR verification and weighing systems ensured raw material accuracy and traceability.

Technologies Used:

  • PLC: Wago (Primary + Redundant)
  • SCADA: Zenon
  • Protocols: Ethernet/IP, Modbus TCP/IP
  • Converters: ATOP

Outcome:

  • Zero downtime via redundant PLCs
  • Automated and safe chemical sequencing
  • Enhanced data integrity and traceability
  • Efficient, scalable process control architecture

Synthetic Leather Coating Machine Automation

Automation of a continuous synthetic leather coating line involving unwinding, coating, heating, cooling, laminating, and winding operations.

Our Solution:

A distributed PLC system (Omron CP2E) with Ethernet FINS enabled synchronized control of servos, VFDs, and proportional valves. Load cells maintained tension, RTDs with DTCs ensured uniform heating, and accumulators allowed roll changeovers without downtime.

Technologies Used:

  • Protocols: Ethernet IP, EtherCAT, Modbus, Analog I/O
  • Hardware: INVT, Alton, Omron, Delta, Exor, Odot

Outcome:

  • Continuous, interruption-free production
  • Precise tension and temperature control
  • Improved coating quality and reduced waste
  • Scalable modular control architecture

Water Filtration System Automation

Automation of a multi-stage industrial water filtration system using Delta PLCs with Ethernet/IP communication for synchronized control and SCADA integration.

Our Solution:

Two master PLCs controlled 36 filtration beds via distributed I/O, managing valves, pumps, and blowers in automatic and manual modes. Cleaning and filtration cycles were fully automated based on timers and level feedback, with SCADA providing real-time monitoring and data logging.

Technologies Used:

  • Protocols: Delta
  • Hardware: Ethernet/IP
  • Interface: Dual Delta HMIs + SCADA

Outcome:

  • Automated filtration and backwash cycles
  • Reduced manual intervention
  • Centralized SCADA-based monitoring
  • Scalable and reliable PLC architecture

Industry 4.0–Enabled Centralized Energy & Machine Monitoring

Implementation of an Industrial IoT (IIoT) architecture connecting 40+ machines and energy meters to a centralized Exor Exware controller, transforming a conventional factory into a data-driven Industry 4.0 ecosystem.

Our Solution:

Using Modbus RS-485 and Modbus TCP, data from energy meters and machines was aggregated through Exware and visualized on ThingsBoard. Wago remote I/Os provided local control and sensor interfacing, while the IIoT gateway enabled secure cloud connectivity. The system delivered real-time insights into machine OEE, downtime, and water consumption, converting raw industrial data into meaningful analytics for decision-making.

Technologies Used:

  • Controller: Exor Exware (IIoT Gateway)
  • Protocols: Modbus RTU/TCP
  • Remote I/O: Wago
  • Platform: ThingsBoard

Outcome:

  • Seamless transition toward Industry 4.0 digitalization
  • Unified energy and production data analytics
  • Real-time OEE and downtime tracking
  • Optimized efficiency through actionable IIoT insights