Not enough people for repetitive work
A monotonous workstation requires continuous staffing, and every absence reduces process output.
Goal: lower dependence on manual operation
Production automation
Production automation - machines and lines tailored to your process
We design, build and commission machines, workstations and automated production lines. We take responsibility for the entire project - from process analysis and engineering, through manufacturing and programming, to installation, acceptance and service.
From problem to solution
When should you consider process automation?
Automation makes business sense when it solves a measurable production problem. Our first discussion usually starts with one of the four areas below.
One operation slows down the entire line
A manual stage cannot keep pace with upstream and downstream operations, creating a bottleneck.
Goal: stable cycle time and higher throughputQuality depends on the operator
Results vary between shifts, increasing rejects, rework and complaints.
Goal: consistent process parameters and qualityObsolete automation causes downtime
Spare parts are difficult to source, failures occur more often, and diagnosing the old control system takes too long.
Goal: modernisation without replacing the entire machine
Proven capabilities
Selected production automation projects
Each machine was developed for a specific process, material and required output. The parameters below come from projects completed by CPP PREMA.
Output: 30 packs/min
Cutting, weighing and packing
PolyCut Pro
Automated line for loading, cutting, conveying, weighing and packing polymer fibres.
Discuss a similar process
Cycle: 20-25 s | 140-180 pcs/h
Workpiece machining
FlexiForm R2
Workstation for the automatic conveying, clamping and edge chamfering of metal workpieces.
Discuss a similar process
4 independent test ports
Testing and quality control
PressureFlex
Workstation for repeatable hose leak testing, adaptable to different hose diameters.
Discuss a similar process
Services
Production process automation - from analysis to service
We tailor the scope to the problem. We can build a new machine, connect workstations into a line or modernise an existing system when this delivers a better business result.
Process analysis and concept
We identify constraints, required cycle time, material characteristics, available space and the current operating method.
Special-purpose machine building
We design machines around the specific parameters of the process, product and plant organisation.
Production line automation
We combine workstations, material handling, inspection and control into one integrated process.
Robotic workstations
We integrate industrial robots where they improve output, quality or occupational safety.
Machine and line modernisation
We replace control systems, drives and components without rebuilding the entire installation.
PLC, HMI and control systems
We design control cabinets, program controllers and operator panels, and commission the system at the customer's site.
How we work
Four stages of project delivery
Each stage ends with a defined deliverable and a decision on whether the project should proceed.
Analysis
The problem, requirements, material, cycle time, installation space and expected outcome.
Engineering
Concept, solution selection, quotation, schedule and detailed engineering documentation.
Build and testing
Manufacturing, assembly, programming, functional testing and preliminary acceptance.
Commissioning and service
On-site installation, commissioning, final acceptance and post-implementation support.
The first step does not begin with a finished machine.
We first identify what actually limits the process and whether automation is the right solution.
The scope and terms of further analysis are agreed during the initial technical consultation.
Why CPP PREMA
One team is responsible for the operation of the entire machine
We combine mechanical, pneumatic, electrical and programming expertise. Our own teams complete the key project stages, making it easier to manage changes, testing and responsibility for the final result.
✓
Mechanical engineering
From the concept and machine model to manufacturing drawings and component preparation.
✓
Pneumatics manufactured in-house
We design and manufacture pneumatic cylinders and valves used in industrial systems.
✓
Electrical systems, PLC and HMI
We prepare the control system, electrical cabinet, software and operator interface.
✓
Assembly and commissioning
We assemble and test the machine before commissioning it at the customer's plant.
✓
Testing and documentation
Before handover, we verify the machine's functions and prepare the agreed technical documentation.
✓
Service and modernisation
We provide post-implementation support and help adapt the machine when the product or process changes.
Cost and return
What determines the business case for automation?
We do not publish a universal price list because two similar operations may require completely different solutions. The process and the current cost of running it must be understood first.
A new machine is not always necessary.
If the mechanical structure of the existing workstation is in good condition, modernising the control system, drives or safety systems may be more cost-effective than complete replacement.
01
Production volume and repeatability
The number of cycles, shifts and operating days affects the potential payback period.
02
Current manual labour cost
The number of operators, operation time and additional costs associated with the workstation organisation.
03
Downtime, rejects and rework
The calculation includes not only labour hours but also the cost of process instability.
04
Solution complexity
Material type, number of product variants, required cycle time, quality control and line integration.
05
New machine or modernisation
We compare the potential outcome of modernising the existing workstation with building a new machine.
Portfolio
Other processes automated by CPP PREMA
We have developed solutions for packing, pressing, bonding, welding, material handling and manipulation processes.
Cardboard box compression
Improved use of warehouse and transport space.
Folding and welding
Automatic processing, folding and stacking of textiles.
EPDM cutting and bonding
Automatic feeding, cutting, adhesive application and joining of seals.
Disposable pillowcase production
Cutting, welding, folding and stacking of the finished product.
Veneer transfer
Handling and transfer of wet and dry material between process stages.
Automatic carton box folding machine
Six-module machine for picking flat cartons from a pallet, automatic changeover, folding and placing the finished cartons on trolleys.
View project
Furniture board turner
ROTAPLATE PRO 3000 - semi-automatic workstation for clamping and turning stacks of boards weighing up to 3,000 kg. Cycle time below 30 seconds.
View project
Felt folding and packing
Line for measuring felt from a reel, cutting, folding, film packing, labelling, grouping and placing finished products in cartons.
View project
Pre-delivery testing
Initialisation, function testing and preliminary acceptance at the CPP PREMA plant.
Commissioning at the customer's site
Installation, commissioning and verification of the machine in the target process.
Documentation and service
Agreed technical documentation plus warranty and post-warranty support.
FAQ
Frequently asked questions about production automation
What is the difference between automation and robotisation?
Automation covers any replacement or reduction of manual work through machines, drives and control systems. Robotisation is one form of automation and specifically uses industrial robots.
Is automation cost-effective for a smaller plant?
It can be when the process is repetitive and generates high labour costs, rejects or downtime. The economics of the specific operation matter more than the size of the plant itself.
Does CPP PREMA modernise machines made by other manufacturers?
Yes. The scope may include replacing PLC/HMI controls, cabinets, drives, pneumatics and selected components of the existing machine.
How should I prepare for the initial consultation?
Prepare a short process description, photos or video, required cycle time, number of product variants, approximate production volume and available installation space.
Do you provide PLC and HMI programming?
Yes. We design and modernise control systems and program PLC controllers and HMI panels for new and existing machines.
Do you provide service after commissioning?
Yes. We provide warranty and post-warranty service for the machines we build, plus support for subsequent modernisation.
Technical contact
Describe the process you want to improve
You do not need a finished machine specification. A description of the current operating method, the problem and the expected result is enough. During the consultation, we will determine what further information is required.
Primary phone
511 544 108
CPP PREMA automation team
Alternative contact
502 829 200
Email
uslugi@cpp-prema.pl
Photos, videos and drawings can be attached directly to your message.
Send a technical enquiry
Describe the process and the problem to be solved. The form will be sent directly to the CPP PREMA automation team.