The challenge
Total Tooling — a Victorian manufacturer with three factories and 80+ staff — nylon-coated components using a manual process: flame-heating parts by hand, then dipping them into nylon powder. It was slow, quality varied with the operator's judgement, and the burn risk was constant.
The solution
Rather than automate the existing process, we re-engineered it: a parallel robotic process built around a carousel and two heating stations, with the robot controller managing heat timing and executing exact, repeatable dip depth. Mechanical design, fabrication, robot integration, electrical and controls — all delivered by our in-house team.
The results
- Increased throughput via parallel heating and dipping
- Controlled, repeatable heating and exact dip depth — consistent coating quality at last
- Operator removed from the flame-and-dip loop entirely; freed for value-adding work
This is what "robot solutions, not robots in boxes" means: the win came from process re-engineering, and the robot made it possible. Explore robotic solutions