Engineered to automate high-speed mask packaging, improve production efficiency, and support scalable medical device manufacturing
A medical device manufacturer had invested in a high-speed surgical mask production system to support growing demand for personal protective equipment. While the production equipment successfully manufactured masks, the packaging process remained entirely manual, creating a bottleneck that limited overall production efficiency.
The manufacturer required an automated solution capable of interfacing directly with the existing mask production line and packaging masks into retail boxes at production speeds of up to 100 masks per minute. The packaging process also required masks to be loaded in a specific orientation, allowing end users to remove individual masks from the box without disturbing the remaining contents.
The project presented several technical challenges. Masks needed to be transferred from the production machine while maintaining control of both the mask body and attached head ties. Product orientation, timing accuracy, box positioning, and machine synchronization were all critical to successful packaging. In addition, the packaging system needed to integrate with equipment supplied by multiple vendors, including a mask production machine from an overseas manufacturer and a separate box erecting system.
The manufacturer partnered with Re:Build DAPR to develop a fully integrated packaging solution capable of automating the final stage of mask production while maintaining throughput and minimizing rejects.
Re:Build DAPR worked closely with the customer to understand the mask production process and evaluate multiple approaches for transferring, orienting, and packaging masks at high speed.
The engineering team analyzed various conveyance and transfer concepts, including vacuum handling, mechanical transfer systems, and alternative actuation methods. Careful consideration was given to machine complexity, reliability, cost, and project schedule when selecting the final system architecture.
A major focus of the project involved synchronizing the packaging equipment with the existing mask production line. Detailed timing studies were performed to optimize sensor placement, servo motion profiles, conveyor speeds, and product detection strategies. The team also evaluated box handling methods to ensure reliable positioning and transport despite inconsistencies in box geometry coming from the upstream box erector.
Because the packaging system relied on equipment from multiple suppliers, Re:Build DAPR collaborated extensively with the customer and upstream machine vendors to address integration challenges, troubleshoot performance issues, and ensure reliable operation across the entire production line.
Re:Build DAPR designed and built a fully integrated mask packaging automation system that interfaces directly with both the mask production machine and box handling equipment.
Masks are transferred from the production line using a precision pinch conveyor system that maintains control of the product while guiding the head ties into the correct orientation. Product detection sensors trigger a servo-driven linear actuator that accurately places masks into boxes positioned below the transfer point.
The system incorporates skew detection technology that identifies improperly oriented masks and automatically rejects them before packaging. A conveyor-based box handling system transports erected boxes into position, squares and aligns them using rails and tamping mechanisms, and advances completed packages to an operator station for final closure.
To address challenges associated with head tie entanglement, Re:Build DAPR developed custom end-of-arm tooling modifications that prevented ties from wrapping around the transfer mechanism during high-speed operation. Additional system refinements ensured reliable handoff between machines and accommodated variations in product presentation and box geometry.
The result was a highly synchronized automation platform capable of packaging masks continuously while maintaining product orientation and minimizing reject rates.
Re:Build DAPR successfully delivered an automated packaging system that integrated seamlessly with both the mask production machine and box erecting equipment.
The completed system achieved packaging rates of approximately 100 masks per minute while maintaining low reject rates and reliable product handling. The automation eliminated a labor-intensive manual packaging operation and enabled the customer to support higher production volumes without increasing staffing requirements.
Beyond the packaging system itself, Re:Build DAPR played a significant role in resolving upstream machine integration challenges and production issues, helping the customer achieve a fully functional manufacturing line despite complications involving multiple equipment suppliers.
The successful implementation strengthened the customer relationship and led to additional opportunities for future automation projects.
The mask packaging system included:
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