Cartoning machine

1-liter bottle cartoning machine. Features:

- One bottle format

- Two box formats with 3x5 and 3x4 matrices

- Nominal rate of 6 boxes per minute

- 220 VAC voltage and 0.6 MPa air pressure

- Allen Bradley Micro800 series PLC and HMI

- Automatic control

- Customer: Dragón

Cycle time was a key factor, so the machine was designed to operate continuously, maintaining the necessary cadence for the production line without sacrificing packaging accuracy. This significantly increased productivity, reducing downtime and eliminating variations between operators.

The results obtained include:

> Increased operational efficiency and reduced manual labor costs.

> Uniform packaging, improving the commercial presentation of the product.

> Lower rejection and waste rates thanks to automatic control.

> Safe operation with protection mechanisms and ergonomics for personnel.

With this solution, Synergy Mechatronics helped strengthen the plant's production capacity, ensuring quality, speed, and reliability in each packaging cycle.

Safety guard

Existing riveting machine for fuse boxes. Features:

- Design of guard based on ISO standards

- Preparation of risk analysis

- Required safety level: PLd / Cat3

- Integration of safety elements such as light curtains, safety contactors, safety valve, and emergency stop

- Safety controller rated for tasks requiring SIL 3 / PLe safety level

- Improved ergonomics and accessibility

- Client: Eaton

The main challenge was to ensure reliable and safe operation for the operator. The existing guard was obsolete and, following a risk analysis, it was determined that it no longer complied with current industrial safety regulations.

Synergy Mechatronics developed the new safety guard design, maintaining the same process productivity while ensuring functional safety for the operator. This ensures that the equipment protects the user even in the event of misuse or tampering.

With this solution, Synergy Mechatronics strengthened Eaton's operational capacity, ensuring efficiency, quality, and reliability in one of its most widely used electrical products globally.

Case packer

Dental floss packaging machine. Features:

- A case format

- A roll format of dental floss

- Nominal rate of 90 cases per minute

- Voltage of 220 VAC and air pressure of 0.6 MPa

- Allen Bradley GuardLogix PLC and PanelView Plus 600 HMI

- Required safety level: PLd / Cat3

- Mando semiautomático

- Client: P&G

The solution includes:

> Controlled feeding of cases and blades.

> Automatic assembly stations with precision adjustment mechanisms.

> Dimensional and functional verification to ensure proper closure and operation.

> Orderly and uniform packaging system, ready for production line or distribution.

The cycle time was carefully calculated to achieve continuous and balanced production, contributing to significant performance optimization without compromising safety or the quality of the final product.

Benefits obtained:

> Higher productivity with less human intervention.

> Reduction of waste and rework, thanks to automatic control.

> Highly consistent presentation and packaging, perfect for consumer sales.

> Ergonomic and safe operation, designed for the well-being of personnel.

With this solution, Synergy Mechatronics strengthened P&G's operational capacity, ensuring efficiency, quality, and reliability in one of its most widely used personal care products globally

Lamp holder

Lamp holder assembly machine. Features:

- A lamp holder format

- Three bag formats

- Nominal rate of 15 lamp holders per minute

- Voltage of 220 VAC and air pressure of 0.6 MPa

- PLC and HMI from B&R

- Required safety level: PLd / Cat3 

-Semi-automatic control

- Client: Eaton

Cycle time was key to ensuring the competitiveness of the production line. Therefore, the machine was designed to maintain continuous and stable operation, significantly increasing productivity without compromising product finish or safety.

Benefits achieved:

> Increased efficiency and reduced operating costs thanks to partial automation.

> Uniform and reliable assemblies, eliminating rework and variations.

> Secure and standardized packaging, ready for handling, storage, or shipping.

> Safe and ergonomic operation, protecting personnel and equipment.

With this solution, Synergy Mechatronics helped strengthen Eaton's production capacity, ensuring speed, precision, and quality in every lamp holder manufactured and packaged

Pump conveyor

Gel dispenser pump guide device. Features:

- One pump format

- Nominal rate of 30 pumps per minute

- Air pressure of 0.6 MPa

- Automatic control

- Client: 4E

Socket assembly machine

Socket assembly machine Features:

- A lamp holder format

- A bag format

- Nominal rate of 30 lamp holders per minute

- 220 VAC voltage and 0.6 MPa air pressure

- Siemens PLC and HMI

- Automatic control

- Client: Btcino

Cycle time was crucial to ensuring the competitiveness of the production line. Therefore, the solution was fully automated, enabling continuous, stable, and high-performance operation, increasing productivity without compromising the finish, precision, or safety of the product.

Benefits achieved:

> Total automation of the process, reducing operating costs and eliminating dependence on manual intervention.

> Consistent and repeatable assemblies, avoiding rework, errors, and variations between parts.

> Standardized and secure packaging, ready for transport, storage, or shipping without additional steps.

> Ergonomic and safe operation, protecting personnel and extending the life of the equipment.

Thanks to this solution, Synergy Mechatronics strengthened Bticino's production capacity, ensuring speed, precision, and consistent quality in every lamp holder manufactured and packaged

Stamp inspection

Seal inspection device. Features:

- One bottle format

- Inspection of two seals

- Nominal rate of 50 bottles per minute

- Voltage of 220 VAC and air pressure of 0.6 MPa

- Allen Bradley Micro800 series PLC and HMI

- Automatic control

- Customer

Control interface update

 Electrical terminal riveting machine. Features:

- Button upgrade for die cutting execution

- Physical position change and button holder manufacturing in PTR

- Modification and upgrade of machinery safety signals

- Upgrade of safety PLC routines

- Increased ergonomics and ease of use

- Client

Hydraulic valve assembly line

Assembly line. Features:

- A valve format

-Automatic O-ring placement system

- PLC and HMI from Allen Bradley 

- Nominal rate of 10 valves per minute

- Indexed band for precision operations

- Component test module

-Semi-automatic control

- Client: Rotoplas

The main challenge of this project was to systematize assembly operations that were previously performed manually. Four manual operations were transformed into four semi-automatic operations, creating a more logical and controlled workflow, reducing errors, and increasing productivity. In summary, this assembly line achieved the following:

> Reduce manual operations from four to just twoIncrease the line's overall productivity

> Reduce errors and improve process repeatability

> Optimize ergonomics and increase operator safety

With this solution, Synergy Mechatronics strengthened Rotoplas's production capacity, ensuring speed, precision, and consistent quality in every valve assembled

Indexed table for robotic cell

Indexed table for tool supply. Features:

- One tool holder format

- Quick change system

- 120 VAC voltage and 0.6 MPa air pressure

- Independent DSP-based controller

- Automatic control

- Academic use