Custom Automation Machinery & Automated Equipment Solutions
Custom Automation Machinery
Elsner Engineering designs and manufactures custom automation machinery, automated equipment, and turnkey automation systems for manufacturing operations across North America. Our custom automated machines streamline production workflows, reduce labor costs, and improve quality control while maintaining the flexibility to adapt as your business grows.
Whether you need a single automated assembly machine or a complete custom automation system, our engineering team transforms manual processes into efficient, reliable automated production. We specialize in custom automation equipment that solves unique manufacturing challenges standard machines cannot address.
Contact us at (717) 637-5991 to discuss your automation goals
Start Your Automation Project
From initial concept to production implementation, our team provides the expertise you need to automate successfully.
Phone: (717) 637-5991 Email: eew@elsnereng.com
Types of Custom Automation Equipment We Build
Every manufacturing operation faces unique challenges. Our custom automated machinery addresses specific production needs that off-the-shelf equipment cannot solve. Here are the most common types of custom automation systems we engineer:
Custom Automated Assembly Machines
Purpose-built assembly automation that handles your exact product configuration, component tolerances, and cycle time requirements. These custom automated machines combine mechanical positioning, part feeding systems, fastening equipment, and quality verification into a single integrated cell. Typical applications include multi-component assembly, press-fitting operations, adhesive dispensing, and threaded fastener installation.
We design assembly automation for products ranging from small electronics to automotive subassemblies, with throughputs from 10 to 300 parts per hour depending on complexity.
Custom Automation Systems for Material Handling
Automated material transport, sorting, buffering, and staging systems that optimize material flow through your facility. Our material handling automation includes custom conveyor systems, robotic pick-and-place cells, automated guided vehicle (AGV) integration, and buffer storage systems.
These systems eliminate manual material movement, reduce work-in-progress inventory, and ensure consistent part orientation for downstream operations. Material handling automation is particularly valuable in high-mix production environments where flexibility is critical.
Custom Automated Packaging Equipment
End-of-line packaging automation designed around your specific product dimensions, packaging materials, and throughput requirements. Our packaging machinery handles cartoning, case packing, palletizing, labeling, and shrink wrapping operations.
Custom packaging automation accommodates products that don't fit standard packaging equipment profiles or require specialized handling due to fragility, weight, or shape. We integrate vision inspection, weight checking, and serialization as needed to meet regulatory requirements.
Custom Automation Machines for Testing & Inspection
Automated quality verification systems that test electrical functionality, mechanical performance, dimensional accuracy, or visual appearance. These custom automated inspection machines eliminate subjective operator decisions and provide documented test results for every unit.
Testing automation can include electrical continuity testing, pressure/leak testing, torque verification, machine vision inspection, coordinate measuring machine (CMM) integration, or functional performance validation. Test results integrate with your quality management system for full traceability.
Custom Robotic Automation Systems
Industrial robot integration customized for your specific application. We work with all major robot brands (FANUC, ABB, KUKA, Yaskawa, Universal Robots) to create robotic cells for welding, material removal, machine tending, palletizing, pick-and-place, and assembly operations.
Our custom robotic systems include all necessary end-of-arm tooling, part fixturing, safety fencing, and control system integration. For collaborative applications, we design cobot cells that work safely alongside human operators.
Industries We Serve With Custom Automation Equipment
Our custom automation machinery operates in diverse manufacturing sectors, including automotive components, medical device manufacturing, consumer packaged goods, electronics assembly, pharmaceutical production, and industrial products. Each industry benefits from our experience designing compliant automation systems that meet regulatory requirements while maximizing efficiency.
Comprehensive Automation Solutions
Our automation capabilities address manufacturing challenges across your production line:
- Full Production Lines: Complete end-to-end automated manufacturing systems
- Standalone Automation Cells: Task-specific machines that integrate with existing production
- Process Automation: Targeted solutions for manual or bottleneck operations
- Material Handling Systems: Automated transport, sorting, and packaging systems. Our contract manufacturing capabilities ensure seamless integration of material handling with your production processes.
- Quality Inspection Equipment: Integrated verification and testing stations
- Control System Integration: Unifying disparate equipment with modern controls
From automating a single critical operation to designing entire production lines, our solutions scale to match your exact needs.
The Custom Automation Process
Our structured approach creates turnkey manufacturing solutions that deliver lasting value:
- Process Assessment: Our team analyzes your current operations, identifying automation opportunities and constraints
- Concept Development: Working with your team, we create automation concepts that address identified needs
- Detailed Engineering: Complete mechanical, electrical, and control system design
- Fabrication & Assembly: In-house precision machining and manufacturing of custom components and system assembly
- Testing & Validation: Rigorous performance testing against specifications
- Installation & Commissioning: On-site setup and startup support
- Training & Documentation: Comprehensive operator and maintenance training
This collaborative process integrates your production knowledge with our automation expertise, resulting in systems that truly meet your manufacturing objectives.
Engineering Excellence in Custom Automation Design
Successful automation requires more than mechanical design - it demands a deep understanding of your manufacturing process, material behavior, and production environment. Our custom automation engineering approach balances technical sophistication with practical manufacturability and maintainability.
Design for Manufacturing & Assembly
Every custom automated machine we design incorporates DFM/DFA principles to ensure reliable, cost-effective production. We select proven components from established suppliers, design for serviceability with accessible adjustment points, and minimize custom-fabricated parts when standard components suffice.
Our mechanical designs account for the realities of production environments - temperature variation, vibration, contamination, and the need for periodic maintenance access. This practical approach delivers automation equipment that performs consistently over years of operation.
Control System Architecture
Modern custom automation systems require sophisticated yet maintainable control systems. We standardize on industrial-grade PLCs (Allen-Bradley, Siemens) and develop HMI interfaces that balance operational capability with user-friendly simplicity.
Our control system design includes comprehensive fault diagnostics, data logging for production monitoring, and remote access capability for technical support. We document all PLC code with clear comments and provide editable source files so your team can make future modifications.
Safety System Integration
All custom automation equipment incorporates appropriate machine safeguarding per ANSI/RIA and OSHA requirements. This includes light curtains, safety scanners, emergency stop circuits, guard door interlocking, and two-hand control stations where appropriate.
We conduct risk assessments during design to identify hazards and implement appropriate safeguarding measures. Our safety systems are designed for intuitive operation - protecting workers without hindering legitimate production activities.
Validation & Performance Testing
Before any custom automated machine leaves our facility, it undergoes rigorous testing that simulates actual production conditions. We run your production materials, verify cycle times, stress-test mechanical components, and validate all control system functions including error recovery.
This thorough testing approach identifies and resolves issues in a controlled environment rather than on your production floor. Most clients visit our facility for Factory Acceptance Testing, providing hands-on operator training while verifying system performance.
Request a process assessment to begin your automation project
Automation Engineering Expertise
Our automation team brings specialized expertise to your project:
- Mechanical Engineering: Robust machine design for 24/7 operation
- Electrical Engineering: Electric distribution and control systems
- Control Systems: PLC programming and HMI development
- Robotics Integration: 6-axis, SCARA, delta, and collaborative robot applications.
- Vision Systems: Machine vision for inspection and guidance
- Pneumatics & Hydraulics: Fluid system design and implementation
This multi-disciplinary approach allows us to develop complete automation solutions in-house, maintaining quality control and project continuity from concept to commissioning. Our contract engineering services provide the design expertise and technical support needed for complex automation projects.
Connect with our engineers to discuss technical requirements
Industries & Applications
Our custom automation systems serve diverse manufacturing sectors:
- Consumer Products: High-speed packaging and assembly
- Medical Devices: Precision assembly with verification, utilizing our advanced 3D printing capabilities for custom fixtures and tooling
- Automotive: Component manufacturing and testing
- Electronics: PCB handling and component placement
- Pharmaceutical: Packaging and material handling
- Food Processing: Hygienic product handling and packaging
Each industry benefits from our application-specific knowledge and experience in developing regulatory-compliant automation systems. Learn more about our industry-specific manufacturing solutions and how we address unique sector requirements.
Control & Integration Capabilities
Modern automation requires sophisticated control systems:
- Allen-Bradley/Rockwell Automation: CompactLogix, ControlLogix platforms
- Siemens: S7 series controllers
- HMI Development: Intuitive operator interfaces with process visualization
- Data Integration: Connection to MES and ERP systems
- Remote Monitoring: Secure access for troubleshooting and support
- Vision System Integration: Cognex, Keyence, and other platforms
We create control systems that provide necessary sophistication without needless complexity, making systems both effective and maintainable.
Custom Automation Equipment Capabilities at a Glance
Understanding our technical capabilities helps determine fit for your application. Here's a quick reference of our typical automation equipment with its specifications:
- Machine Size Range: Small benchtop cells (4'×4') to large production lines (100+ linear feet)
- Cycle Time Range: 2 seconds/part (high-speed) to 5+ minutes/part (complex assembly)
- Typical Production Volume: 10-300 parts per hour, depending on complexity
- Robot Payload: Up to 500 kg (collaborative robots to heavy-duty industrial)
- Control Systems: Allen-Bradley CompactLogix/ControlLogix, Siemens S7-1200/1500 series
- Vision Systems: Cognex, Keyence, Omron platforms for inspection and guidance
- Safety Standards: ANSI/RIA R15.06, OSHA 1910.212, ISO 13849-1 Category 3/PLd or higher
- Industries Served: Automotive, medical device, consumer products, electronics, pharmaceutical, food processing
- Typical Project Timeline: 12-40 weeks, depending on complexity
- Service Area: North America (primary: Mid-Atlantic and Northeast regions)
Specifications vary by application. Contact our engineering team to discuss your specific requirements.
Rigorous Testing & Validation
Every automation system undergoes comprehensive testing before deployment:
- Factory Acceptance Testing (FAT): Verification of all functions and performance metrics
- Production Simulation: Running actual production materials and parameters
- Control System Validation: Verification of all operational modes and safety functions
- Operator Training: Hands-on system familiarization during testing
- Documentation Review: Confirmation of all operating and maintenance procedures
This thorough testing process identifies and resolves issues before installation, minimizing production disruption and startup challenges.
Why Choose Our Automation Solutions
- Manufacturing Focus: Practical solutions that deliver real production benefits
- In-house Capabilities: Complete mechanical, electrical, and control system design
- Production Experience: Extensive knowledge of manufacturing environments
- Integration Expertise: Seamless connection with existing equipment
- Post-Installation Support: Ongoing service and optimization
- Scalable Solutions: From simple fixtures to complete production lines
Partner with us to develop automation systems that transform your manufacturing capabilities and position your business for growth.
Benefits of Custom Automation
Investing in purpose-built automation delivers significant advantages:
- Increased Production Capacity: Boost output with faster, more consistent operation
- Improved Quality: Eliminate human variability from critical processes
- Labor Cost Reduction: Redeploy staff to higher-value activities
- Enhanced Safety: Remove operators from hazardous tasks
- Space Optimization: Compact machine footprints maximize facility utilization
- Data Collection: Integrated production monitoring and analytics
- Competitive Advantage: Manufacturing capabilities unavailable to competitors
Our clients typically see ROI within 12-24 months for targeted automation projects, with long-term benefits extending well beyond initial investment recovery.
Request an Automation Consultation
Take the first step toward manufacturing transformation. Contact us today to discuss how our custom automation solutions can improve your production efficiency and product quality.
Frequently Asked Questions
Our clients commonly ask these questions about our custom automation services.
For additional information, please contact our engineering team directly.
We evaluate multiple factors including production volume, process consistency, labor requirements, quality concerns, and safety considerations. Our assessment examines cycle times, material handling needs, inspection requirements, and process variability. We conduct a detailed ROI analysis comparing current operation costs against expected automation benefits. Even processes with some variability can often be automated with proper sensing and adaptive control strategies. Our team provides honest recommendations about automation feasibility.
Successful automation projects require collaboration between our engineers and your production team. We typically need input from your process experts, maintenance staff, and operators at key project stages. This includes initial process documentation, concept review, design approval, and testing phases. Your team's knowledge about product specifications, material behavior, and operational constraints is invaluable. Most clients assign a project coordinator to facilitate communication, but we adapt our approach based on your available resources and preferences.
Yes, we specialize in creating automation solutions that work with your current production assets. We can design systems that interface mechanically and electronically with existing machines, adding capability without replacing functional equipment. Our control systems can communicate with older equipment using various protocols or hardwired signals. Before designing integration points, we thoroughly document existing machine capabilities, control systems, and communication options. For equipment lacking modern connectivity, we can add sensors and controls to enable integration through our machine retrofit and upgrade services.
Our comprehensive training and documentation package includes operator training, maintenance training, mechanical and electrical drawings, control system documentation, spare parts lists, and troubleshooting guides. Operator training covers daily operation, product changeovers, basic troubleshooting, and safety procedures. Maintenance training addresses preventive maintenance requirements, component replacement, and advanced troubleshooting. All documentation is provided in electronic and hard copy formats. We can customize training programs based on your team's technical capabilities and create specialized maintenance documentation for your particular needs.
We provide multiple levels of post-installation support to help your automation system perform optimally long-term. Immediate post-startup support includes on-site technical assistance during initial production runs. Our standard warranty covers parts and labor for mechanical, electrical, and control system components. Beyond warranty, we offer service contracts with preventive maintenance visits, priority emergency response, remote system monitoring, and performance optimization services. For clients with internal maintenance capabilities, we provide technical phone support, spare parts management, and periodic system audits. We view every automation project as a long-term partnership.
Custom automation equipment costs vary significantly based on complexity, production volume requirements, and level of integration. Simple single-function automated machines typically range from $50,000 to $150,000. Multi-station automation systems with robotic integration generally cost $200,000 to $500,000. Complete production lines with multiple automation cells can exceed $1 million.
However, cost should be evaluated against ROI. Most custom automation projects achieve payback within 12-24 months through labor savings, increased throughput, and improved quality. We provide detailed ROI analysis during the proposal process, calculating the expected payback period based on your specific production economics. Many clients find that not automating carries higher long-term costs than the initial automation investment.
Timeline depends on system complexity and the current project backlog. Simple automation machines typically require 12-16 weeks from contract signing to delivery. Moderately complex multi-station systems usually take 20-28 weeks. Large-scale production lines or systems with extensive custom engineering may require 9-12 months.
Our project timeline includes concept development (2-3 weeks), detailed design (4-6 weeks), component procurement (4-8 weeks), fabrication and assembly (6-10 weeks), and testing/validation (2-3 weeks). We provide detailed project schedules with milestone dates and maintain regular communication throughout the process. Many clients prefer longer lead times that allow for thorough engineering and testing rather than rushed projects that compromise quality.
Yes, we frequently modernize and upgrade existing custom automation machinery. Common retrofits include replacing obsolete control systems with modern PLCs, adding vision inspection to existing machines, integrating robots into manual cells, and upgrading mechanical components for faster cycle times.
Retrofitting existing automation equipment often costs 30-50% less than new machine construction while delivering substantial performance improvements. We assess the condition of existing mechanical structures, evaluate control system upgrade paths, and determine if retrofit makes economic sense compared to new equipment. Some machines are excellent retrofit candidates, while others are better replaced - we provide honest recommendations based on your specific situation and production requirements.