From a labour-intensive manual process to a fully automated, multi-size production platform, this high-speed coiling and packaging system was engineered, prototyped and built in-house at our Dundalk Design & Build Centre.

At a Glance

• 7 integrated process stages
• 4 servo-controlled coiling heads
• 1 platform for a full product family
• End-to-end automation, from tray denesting to sealing

Project Snapshot

• Application: Coiling, tray loading & transfer to sealing
• Built at: Reliance Design & Build Centre, Dundalk
• Our scope: Prototyping, process development, proof of concept, mechanical & controls design, build and integration
• Core technology: Servo motion, multi-head robotic transfer, precision indexing

The Challenge: A Process That Depended on People at Every Step

The existing production process was highly operator-dependent, requiring significant manual intervention across product handling, coiling and packaging.

The brief was to design and develop a high-speed, fully automated solution able to handle a complete family of products across multiple sizes, delivering consistent product presentation, higher throughput and reduced labour dependency.

The Solution: One Integrated Platform, Engineered Stage by Stage

Through extensive prototyping, process development and proof-of-concept testing, our engineers developed a fully integrated system that optimises every stage of production, from singulation through to final packaging.

1. Tray denesting – automated denesting for reliable product presentation
2. Singulation – high-speed singulation to accurately control product flow
3. Indexing – cleated indexing conveyors for precise product positioning
4. Robotic transfer – multi-head robotic transfer for high-speed handling
5. Servo-driven multi-head coiling – repeatable coil formation across multiple product sizes
6. Tray insertion – automated product insertion into packaging trays
7. Transfer to seal – integrated tray handling and transfer to downstream sealing

Servo-driven motion, precision indexing and multi-head handling combine to sustain high throughput with consistent, repeatable product quality.

The Outcome: A Labour-Intensive Process, Transformed

• Higher throughput – increased production output
• Less manual labour – significant reduction in operator intervention
• Repeatability – improved process consistency and control
• Multi-size handling – automated handling across multiple sizes
• Line integration – seamless hand-off to downstream packaging
• Data logging & database integration – connectivity for full production traceability

Concept to Lifetime Support, Under One Roof

Every stage was designed, prototyped and built at our Dundalk Design & Build Centre. And because Reliance Automation also supplies an extensive range of the automation components we build with, the same team stands behind the machine for spares and support throughout its life.

Have a manual process you want to automate? Talk to our engineering team about prototyping and building a solution at our Dundalk Design & Build Centre.