Production line automation
At EcoSurfaces
EcoSurfaces is a locally owned maker of silica-free benchtop surfaces. They asked us to automate part of their stone slab production line: a calibrator, a turntable and a surface polisher.
Challenges
Quality at a fair price
The benchtops had to be high quality and still affordable.
High labour cost
Each imported machine needed two or three operators to watch production quality.
Second-hand machines
The machines were second-hand imports with little documentation, and their safety was not to Australian standards.
Solution
Automated production line
Every machine on the line was automated with a PLC and extra sensors. The operator screen runs on a tablet, so the operator can run the line while walking around the machines.
Centralised control
One control system monitors and controls every machine on the line. Adjustments are made automatically or from the operator screens.
Updated control panels
A production and risk assessment set the level of upgrade for each machine’s electrical system. Every machine got schematics and documentation, and the control system can be reached remotely for support.
Results
27% fewer errors
Most manual steps are now automatic and the machines are monitored constantly. Shift start, tooling, and production starts and stops are recorded automatically.
25% lower labour cost
Machines that needed two or three operators each now need one person to watch the whole line. Most production runs in automatic.
New control system
New electrical panels to Australian standards, with the safety functions they require, and operator screens built for this process.
Client testimonial
Rhys Bennett, General Manager
ControlX has provided outstanding support for our automation needs at Eco Surfaces Australia. Their expertise and system integration have allowed us to streamline our production process, improving both efficiency and output. With their solutions, we are now confidently producing up to 7 slabs per day. Their team has been professional, responsive, and highly skilled, making them a key partner in enhancing our manufacturing capabilities.
We recommend ControlX.