The Consumer Product Filling - Capping - Packaging System is an advanced, automated solution designed to process empty, unlabeled bottles through a comprehensive sequence of operations: labeling, filling, capping, carton loading, case packing, and palletizing. Engineered to operate at a gross production rate of 160 bottles per minute (bpm), the system integrates cutting-edge robotics, conveyors, and vision technology to ensure efficiency and precision. The process begins with operators loading empty bottles into a Farason Bottle Sorting and Feeding Machine hopper. Bottles are sorted, conveyed, and oriented via an AC-driven Vision Conveyor and ABB IRB-360 Delta Robot, which places them into staging nests. A second ABB IRB-1200 Six-Axis Robot then transfers bottles (6-Up) for air rinsing and placement onto a dual-sided flat belt conveyor. To optimize throughput, a duplicate Farason sorting system is included. Downstream, bottles are labeled using two dedicated Inline Nita Labeling Machines—one for each product variant—followed by vision inspection for label accuracy. Bottles then enter an AB Servo-driven timing screw for spacing and are picked (5-Up) by ABB IRB-910SC SCARA Robots and placed onto Magnemotion vehicles. These vehicles transport bottles through puck charging, filling (via dual independent cells with five fill heads each), and capping operations, accommodating both product variants. Caps are applied using AB Servo torque heads and custom feeder assemblies, with additional Dose cups added by another SCARA robot. Post-filling, bottles pass through Axon Aurora 4.0 SS sleever machines for sleeve application, followed by heat/steam shrinking and drying. A Domino laser marks codes onto labels, and bottles are inspected before being carton-loaded by an ABB IRB-1200 Six-Axis Robot into a Douglas Vectra Cartoner. Cartons proceed to a dual-robot Case Packer Loading Machine and a Douglas CpONE Case Packer. Cases are printed, Cognex-inspected, and palletized by an ABB IRB-460 robot, with pallets stretch-wrapped by a Lantech QL Series machine. Completed products exit the machine on an outfeed conveyor for operator removal.

The Automated Encapsulation Machine handles coins of various sizes and denominations and encapsulates them between two acrylic capsule halves at a gross production rate of 25 coins per minute. Coins and capsules populate trays that get transferred from a magazine stacker onto a system of conveyor belts to travel through the machine production process. A vision-guided robotic system, consisting of three (3) separate ABB Model IRB-910 Inverted SCARA robots, positions the coins within the bottom and top acrylic capsule halves. Once the coin is positioned, encapsulated, and centered the encapsulation press secures the halves together to finalize the production sequence. A fourth robot stacks empty top and coin trays in a drawer to be removed by an ABB Model IRB-1200 Six-Axis Robot. This robot is also tasked, during change over operations, with changing out the assembly conveyor fixtures designated for the various coin denominations and sizes. Completed products exit the machine on an outfeed conveyor for operator removal.

Located about the perimeter of a centrally placed Magnemotion Intelligent Conveyor loop with custom vehicles are stations of various machine operations to produce a medical device adhesive application pen at a rate of 30 per minute. On a single side of the length of the machine, all individual pen components are fed in via vibratory bulk supply hoppers or ACdriven elevating prefeeders. Allcomponents, when fed from bulk, drop onto backlit rotary disk feeders that workin conjunction with above mounted Cognex vision cameras which in turn relaycomponent position data to Fanuc LR Mate Six-Axis Robots. Each robot is responsible for loading its own designated part with either vacuum or pneumatic gripper end of arm tools. With components loaded onto the Magnemotion track, a series of Allen Bradley Servo and Pneumatic pick and place operations are present along the opposite side of the machine to pick, place, press, reorient, reposition and manipulate the components to produce a completed adhesive pen assembly. Following all machine operations, a Cognex final vision inspection is present to verify correct assembly. Good adhesive pens are picked and placed into the platens of a Farason supplied and integrated Starview Blister Sealing Machine.

The Oral Test Device Assembly Machine was designed and built to streamline the manufacturability of a product for a local Medical Device company. The machine’s purpose is to sort, feed and assemble Top and Bottom Housings, Test Strips and Wicks into an Oral Test Device at a rate of 32 parts per minute. Throughout the part assembly process, components are fed and processed on a Camco Precision Link Indexing Conveyor with custom Delrin fixtures designed to accurately locate and align components within a nest. From an overall process perspective, operators load plastic bottom housings, top housings and Wicks, from bulk, into the supply hopper of AC driven prefeeders where parts are then fed through a series of conveyors and part manipulating devices which are the key building blocks comprising of a Farason custom sorting and feeding system also referred to as a Farafeeder. Dedicated feeder Fanuc SCARA and six-axis robots, in conjunction with top mounted vision cameras, top lighting and encoder tracking of vision conveyors along with vacuum end of arm tools, picks the components, presented in a single layer, randomly on the conveyor belt, and places them within a conveyor fixture. Throughout the assembly process, the sub-assembly receives in process Keyence vision camera inspections for part presence and location. With all main components loaded, a final Fanuc SCARA robot picks sub-assembled Oral Testers and places them within the nests of Branson Ultrasonic Welders where they are fully welded, assembled and placed back within the fixtures of a Camco Precision Link Indexing Conveyor. Subsequent to completing the assembly, a final component is placed, a part label from a CTM Label Applicator/Placer. A final Keyence vision camera inspection takes place to verify all labels are present and located within the customers specifications. An AB Servo/Pneumatic dual axis pick and place offloads good parts thereby completing the assembly process of the Oral Test Device.