Integrating Automation Into Converting Production Workflows

The introduction of automation to manufacturing facilities has drastically changed the face of the industry. With these systems, facilities can automate labor-intensive tasks that human workers would otherwise do. Whether performing a simple task or more complex operations, automation integration can significantly enhance productivity, efficiency, output, worker safety, and precision.

Read on to learn how to select from the various converting options, choose a reputable provider, assess your converting needs, and more.

Automation Solutions

TPC Converting offers the following automated converting solutions.

Robot Tape Applicators
Robot Tape Applicators

Robotic arms with precision applicator heads can quickly and efficiently apply pressure-sensitive adhesives (PSA). These tape machines are programmed to process spooled tape and convert it for different lengths, widths, and surfaces, helping to reduce waste and improve uniformity. Key features include:
- Precision. Our automated tape applicators can apply tape with accuracy, handling complex patterns, curves, and 3D geometries.
- Consistency. Automation reduces errors and improves product quality by eliminating the variability often caused by worker fatigue.
- Efficient material utilization. Robotic tape applicators have cut-to-length mechanisms that can optimize material usage without interruption.
Linear Tape Applicators
Linear Tape Applicators

Our ALTA linear tape applicator is an automatic, non-robotic tape applicator that can add an extended release liner to a substrate. The liner is easy to remove, enabling immediate application of your materials. The process can apply single-coated or double-coated tape to parts in a linear or pattern application. Using ALTA can eliminate the need for expensive assembly aids like pull tabs and extended liners. The automatic tape applicator can also reduce the amount of material needed by applying tape in efficient patterns and adding a common liner. For example, the machine can apply two inches of tape, skip two inches, apply two inches, and so on, to reduce overall material utilization.
Automated Protective Film Applicators
Automated Protective Film Applicators

Our custom protective film automation equipment precisely cuts and applies film to product surfaces for a broad range of industries, including automotive, appliances, building materials, construction, and electronics.

These specialized systems help eliminate inconsistencies often found in manual applicators, offering the following benefits:
- Faster production cycles
- Enhanced productivity
- Ideal for repetitive tasks
- Accommodate intricate designs
- Increased throughput
- Reduced errors

Advantages of Converting Automation

The automation integration of robotics in manufacturing converting equipment offers the following advantages.

Increased Productivity and Efficiency

Converting automation can significantly boost productivity and efficiency, providing benefits that include:

24/7 continuous operation without the risk of human fatigue
Faster performance than humans in a wide variety of tasks
Increased output
Reduced cycle times

TPC Converting has slitting and rewinding capabilities to deliver large-format rolls, maximizing the time between roll changeovers.

Improved Workplace Safety

Robots can make the workplace considerably safer for human workers by taking over repetitive, dangerous tasks, such as manual cutting. Reducing human involvement lowers the risk of accidents and injuries.

Long-Term Cost Savings

The long-term benefits of automation integration far outweigh the financial investment, with robots offering the following benefits:

Increased production yields
Minimized waste
Reduced labor costs
Reduced material costs
Quick return on investment (ROI) and cost savings over time

Assess Needs

Analyze your current converted material use to identify applications that can be streamlined through automation. The best processes to replace with automation are those where fatigue or human error can cause inconsistencies and processes that require consistent speed and precision. Determining what to automate and how it can improve efficiency in your facility is the first step to making an informed decision for your production requirements.

Partner With a Reliable Vendor

Partnering with a reliable vendor such as TPC Converting is the key to taking advantage of automated converting solutions. Unlike single-product suppliers that may solely focus on their products, we offer a comprehensive selection of top-quality automated equipment to meet a variety of converting needs. In addition to providing automation integration solutions, TPC Converting can help train your team on how to use the new equipment in your specific production line.

Make a Plan

Once you identify which area of your manufacturing process is best suited for automation, planning how to integrate the automation is crucial. Here is what the planning stage typically entails:

Determine the scope of the automation.
Set realistic and achievable timelines.
Consider how the automation will impact current production processes.

Working with an experienced vendor such as TPC Converting will ensure automation integration occurs with minimal disruptions to current operations. You may need to schedule implementation during downtime or gradually phase in automation to achieve optimal results. It is also essential to look past immediate business needs and acknowledge the potential of investing in an automated converting solution that can grow with your future manufacturing processes.

Planning for the future is a key element of developing a successful automation strategy that is adaptable and capable of evolving with technological advancements and market demands. To offset the cost of new technologies and equipment, customers must consider how automation will benefit operations in the long run and not just in the short term.

Train Staff

A skilled workforce is necessary for operating and maintaining the newly acquired automation equipment. TPC will be there every step of the way, ensuring your operators are trained and equipment is running smoothly. Automated processes and systems also make it easier to train new employees, reducing onboarding times and streamlining operations.

TPC Automation

TPC Converting is your partner in automating your packaging or assembly operation. In addition to providing converted products and services, we can analyze your specific production line and present custom solutions that work for your unique products, budget, and facility. As your business grows, we help you scale efficiently and cost-effectively to support your long-term success.

Contact TPC Converting for Converting Automation

Over the past five decades, TPC Converting has developed long-lasting relationships with thousands of loyal customers. Our converting expertise helps us deliver innovative automation solutions that improve manufacturing efficiency and overcome bottlenecks in the production process.

Our skilled team is consistently trained in the latest industry trends in converting so that we can continue to be a trusted source of knowledge for our customers. We specialize in helping you determine the optimal methods for converting your materials, whether it’s precision slitting, rotary die cutting, laminating, or any other converting process.

Contact us today to learn more about how we can meet the demands of your next project.

Integrating Automation with Converted Solutions

Automation Solutions

Robot Tape Applicators

Linear Tape Applicators

Automated Protective Film Applicators

Advantages of Converting Automation

Increased Productivity and Efficiency

Improved Workplace Safety

Long-Term Cost Savings

Assess Needs

Partner With a Reliable Vendor

Make a Plan

Train Staff

TPC Automation

Contact TPC Converting for Converting Automation