Safe handling of large reels
The equipment had to handle workpieces up to 1,000 mm in diameter and 1,600 mm in length while interfacing with the existing machine's magazine.
CPP PREMA Projects
Selected automation projects - machines and production lines
We design and commission special-purpose machines, test rigs and automated production lines. The projects below show how we combine mechanical engineering, pneumatics, hydraulics, electrical systems and controls into solutions tailored to each customer's process.
7 featured projects
Machines, workstations and production lines for different processes
One project partner
Design, manufacturing, programming, installation and commissioning
In-house engineering expertise
Mechanical engineering, pneumatics, hydraulics, electrical systems, PLC and HMI
Integration with existing processes
New equipment and modernisation of existing workstations
Selected production automation projects
Each project began with a different process, material and set of technical constraints. These case studies present the scope of each solution and verified equipment parameters.
Transport and loading
JUMBY reel lift
Automated feeding of large reels into the infeed magazine of an unwinding machine.
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Testing and quality control
Door test rig
Repeatable opening, closing and shock resistance tests.
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Profile processing
Punching aluminium profiles
An automatic punching cycle starts after the profile is positioned in the fixture.
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Cutting and packaging
Felt folding line
Six process stages - from reel loading to the finished carton.
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Packaging forming
Automatic carton folding
A six-module machine handling two carton formats.
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Transport and stacking
Panel handling after sanding
Automated removal and stacking of panels on a scissor lift.
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Heavy load handling
Furniture panel turner
Semi-automatic turning of panel stacks weighing up to 3,000 kg.
View projectReel lift for an unwinding machine
The objective was to automate the feeding of large reels into the infeed magazine of an unwinding machine and reduce operator involvement in every loading cycle.
Automated JUMBY reel lift
We developed two design variants of the lift, adapted to the production hall layout and the required reel-feeding method.
How the equipment works
The welded steel structure uses hydraulic cylinders and an electrical control system. The lift picks up the reel and feeds it into the unwinding machine's magazine.
CPP PREMA scope
- development of two design variants,
- detailed engineering and equipment manufacturing,
- transport, installation and commissioning at the customer's site,
- integration of the safety fencing with the interfacing machine's safety system.
Do you have a similar loading process?
Describe the material, its dimensions and the required feeding method.
Discuss your project
Door durability test rig
The test rig automates repeatable door opening, closing and load tests in accordance with the requirements of the specified test standards.
Repeatable execution of multiple cycles
The test requires the same sequence of movements and loads to be maintained for a programmed number of repetitions.
Two tests in one test rig
The machine performs repeated opening and closing tests as well as shock resistance tests.
Test scope
- resistance to repeated opening and closing according to PN-EN 1191:2013-06E,
- shock resistance testing according to PN-B-06079:1998,
- cycle count programming from the operator panel,
- door installation in a frame that simulates a wall.
Control system
The control system is based on a PLC connected to a touchscreen panel used to enter test parameters and monitor the test sequence.
Do you need a custom test rig?
Provide the standard, test scope and dimensions of the product to be tested.
Discuss your project
Punching holes in aluminium profiles
The workstation produces a repeatable cut-out for a latch after the profile has been correctly positioned in the fixture assigned to the relevant product variant.
Consistent position of the punched hole
Every profile must be positioned in exactly the same location to maintain repeatable geometry of the finished component.
Automatic cycle after loading
After the profile is loaded, the workstation starts the power unit and the actuator driving the punch. A light signal indicates that the process is complete.
CPP PREMA scope
- mechanical and electrical design of the workstation,
- manufacture of the profile positioning system,
- development and commissioning of the automatic punching cycle,
- equipment installation at the customer's plant.
Do you have a repetitive machining operation?
Send us the component drawing and the required positioning method.
Discuss your project
Measuring, folding and packaging felt
The line combines consecutive operations - from reel loading, measuring and folding to packaging, labelling and placing the finished products in a carton.
Combining multiple process stages
The material must be measured, cut, folded twice, wrapped in film, labelled and grouped.
One line with six stations
Individual modules transfer the product between stages and complete the process by placing the required number of finished items in a carton.
Production line stages
- reel loading using a forklift truck,
- material measuring with encoder-based length control,
- cutting and double folding to the required format,
- film wrapping and heat sealing,
- automatic label application,
- grouping and placing the finished products in a carton.
The working area is protected by safety fencing, while access to the reel-loading
area is monitored by safety light curtains.
Do you have a multi-stage packaging process?
Describe the material, product variants and the required final format.
Discuss your project
Automatic carton folding
The six-module machine picks flat carton blanks from a pallet, folds them and places them on trolleys. The system handles two formats with automatic changeover.
Two formats and continuous output handling
The machine had to handle different carton sizes and automatically transfer the finished packaging to the next process stage.
Six integrated modules
The machine combines pallet picking, buffering, folding, transport and loading of finished cartons onto a trolley.
Machine modules
- pallet lift and carton picking with a vacuum gripper,
- buffer with automatic changeover,
- complete carton-folding module,
- transport to the collection point,
- empty trolley magazine,
- placement of folded cartons and discharge of the loaded trolley.
Access zones are protected by safety fencing, polycarbonate guards, light curtains
and photoelectric safety barriers.
Would you like to automate packaging forming?
Provide the formats, blank delivery method and required output method.
Discuss your project
Furniture panel handling after sanding
The workstation receives large panels directly after sanding and stacks them on an existing scissor lift without interfering with the operation of the sanding machine.
Integration with existing equipment
The new workstation had to interface with the sanding machine and scissor lift already operating at the plant.
Gripping, transport and stacking
Two vacuum grippers transfer the panel, while retractable rollers enable positioning and unobstructed placement on the stack.
How the equipment works
Guide rollers position the panel at the infeed. Before gripping, the surface is cleaned with an air blast. The grippers lift the workpiece and transfer it above the scissor lift, while the rollers retract before the panel is placed on the stack.
CPP PREMA scope
- concept development and approval,
- equipment design and manufacturing,
- testing at the CPP PREMA facility,
- transport, installation and commissioning at the customer's site.
The sanding machine and scissor lift were not included in the scope of supply.
The CPP PREMA workstation was integrated with the customer's existing equipment.
Do you need a new workstation in an existing line?
Describe the interfacing equipment, available space and workpiece transfer method.
Discuss your project
ROTAPLATE PRO 3000 furniture panel turner
This semi-automatic workstation clamps and turns furniture panel stacks weighing up to 3,000 kg. The operator loads and unloads the stack using a forklift truck.
Turning a stack weighing up to 3 tonnes
The process requires controlled clamping, turning and release of a large stack without damaging the panels.
Hydraulic drive and automatic cycle
The operator starts the sequence from the control panel, while the hydraulic system clamps and turns the stack.
Main workstation assemblies
- main frame and lower rotating frame,
- hydraulic clamping system for the panel stack,
- turning assembly and fall-prevention system,
- control cabinet and operator control panel,
- signal tower, safety light curtain and emergency stop system.
Documentation and operation
We prepared an operating manual for the workstation covering safety procedures, a description of the hydraulic system and maintenance recommendations.
Do you need to handle a heavy or oversized component?
Provide its weight, dimensions, loading method and required movement.
Discuss your project
What CPP PREMA delivers
We tailor the scope to each project. One team handles the key stages, ensuring clear responsibility for the machine's operation.
Process analysis
Requirements, material, cycle time, available space and interfaces with other equipment.
Engineering design
Concept, mechanical engineering, pneumatics or hydraulics, electrical systems, safety and controls.
Manufacturing and testing
Manufacturing, assembly, programming and functional testing before delivery.
Commissioning
Transport, on-site installation, acceptance, documentation and service support.
Technical contact
View our complete production automation capabilities
Do you have a process worth automating?
Send us a process description, photos or a video, along with basic information about the workpiece. You do not need a complete machine specification - we will define the scope during a technical consultation.
Main phone number
511 544 108
CPP PREMA Automation Department
Alternative contact
502 829 200
Email
uslugi@cpp-prema.pl
You can attach technical materials to your message.
Send a technical enquiry
Describe the process, the problem and the expected result. Your message will be sent directly to the CPP PREMA automation team.