Fully automated line for pad printing and precise wax dispensing on plates
For a client, we developed a complex custom automated line designed for fully automatic processing of plates. The line ensures reliable, repeatable, and fast processing with a built-in system for optical quality control and automatic rejection of defects.
Initial challenge — The client wanted to reduce manual labor, increase processing capacity, and achieve high pad-print quality and precise wax dosing. The existing process was slow, inconsistent, and challenging for operators, with a large margin for error.
Result — A comprehensive solution that provides greater productivity, repeatability, quality control, and operator relief. All processes are fully automated.
Solution description
With the automated line’s design, we connected multiple processes into a single flow — from plate preparation with a vibratory feeder, pad-printing, wax filling, and final placement into trays for transport trolleys.
The control of the plates is performed optically with integrated cameras.
This ensures a stable process with a high degree of automation and minimal human intervention.
Benefits for the client:
- reduced manual labor and ability to control multiple lines with a single operator,
- higher productivity due to uninterrupted automated flow,
- precision and traceability at all process steps,
- reduced defects thanks to 100% visual control and automatic rejection of faulty pieces,
- flexibility for future upgrades of the line.
Line operation — step by step
1. Loading and orienting the plates – Plates are manually poured into a vibratory feeder, where they are oriented and routed onto the production line.
2. Recognition and rotation – The camera detects plate orientation. If a plate is incorrectly oriented, the system uses a gripper and a pneumatic cylinder to rotate it into the correct position.
3. Pad printing – The plate is accurately positioned and printed with the selected motif using an automated pad-printing system.
4. Wax dispensing – At the next station, a predefined amount of wax is accurately dispensed into a recess on the plate.
5. Cooling of wax during transport – The plate moves forward on the conveyor while the wax cools.
6. Quality control and sorting – The camera checks the pad-print and wax filling. Bad items are automatically removed, while good ones move forward.
7. Stacking into trolleys – At the end of the line, good plates are stacked on trays in a trolley, ready for further processing or transport.
Pad printing and wax dispensing line for plates
Orientation verification, rotation, and printing of plates
Quality control of pad printing and wax filling
Inspection with automatic rejection of defective pieces and stacking of plates on trays in a trolley