SDC’s expertise in automated assembly systems spoke for itself when a new customer found themselves in need of a custom wick insertion machine. With modifications to their current product, this machine needed to be fully automated and equipped to feed its own parts to maintain a consistent run rate.
This automated assembly machine needed to insert polyester wicks with high-speed and precision while still following OSHA safety compliance. Vibratory feeder bowls with inline tracks were determined to be the best way to feed parts to the machine. Due to the wick material, a custom automatic wick inserter was designed to accurately join the parts at the insertion station.
The SDC team customized a high-speed automated assembly machine to manufacture wicks for use in fragrance products. Although the product consisted of two seemingly simple parts, it required precise movement for smooth and continuous operation.
The automated wick assembly machine is designed to efficiently assemble at a rate of 140 parts per minute using a parallel processing system. The machine employs an indexing turret to operate two assembly stations simultaneously—one on each side of the dial. As the dial indexes at 70 cycles per minute, it produces two fully assembled wicks per cycle, doubling the output capacity while maintaining high precision. This dual-sided operation ensures continuous productivity and reduces cycle time, optimizing assembly throughput.
Custom Solution Tailored to Customer Needs: By leveraging our expertise in automated assembly systems, SDC delivered a fully customized, high-speed system that addressed the unique requirements of the customer’s product. This tailored solution, designed for high precision and continuous operation solidified SDC’s reputation as a flexible and innovative machine builder.
Streamlined Production and High Throughput: The machine’s dual-sided indexing turret design, operating at 140 parts per minute, effectively doubles the output capacity without sacrificing precision. This high throughput ensures the customer can meet demand efficiently and allow for uninterrupted production, improving overall productivity.
Enhanced Quality Assurance and Reduced Waste: Through the use of sensors to verify correct part placement and the use of vision to verify part quality, the machine guarantees that only properly assembled parts are sent forward, reducing the likelihood of defective products. Automatic sorting into bins and rejection of faulty parts further improves quality control, minimizing waste and reducing the need for rework or manual inspection.
Optimized Safety and Compliance: With full adherence to OSHA safety requirements, the automated system not only meets critical safety standards but also reduces the risk of workplace injuries. The use of safety mechanisms like physical guarding and safety sensors built into the system protect operators, contributing to a safer and more compliant work environment.
The sequence of operations begins with a collar being loaded into the dial from a feeder bowl. Once the collar is positioned, a sensor verifies its presence and orientation. A wick, fed from a separate bowl, is then inserted into the collar from above, followed by sensor verification to ensure the wick is correctly placed. After assembly, good parts are automatically sorted into bins A and B for further handling, while any rejected parts are directed to a separate reject bin for quality control. A final sensor confirms the fixture is empty before the assembly process repeats. This automated workflow guarantees high-speed, reliable assembly with minimal downtime and maximum production efficiency.
The new custom wick insertion machine proved to be a success for our customer. The SDC team designed and built a system that could work quickly, safely, and accurately, making 140 parts every minute. By using smart technology and careful planning, the machine was able to keep production running smoothly while meeting all the required safety rules. This helped our customer save time, reduce waste, and get a high-quality product every time.
In the end, this project showed how SDC’s knowledge and skills in consumer product manufacturing can turn a challenge into a custom solution that works. The machine’s fast speed, careful quality checks, and safe design gave the customer exactly what they needed—and more. Thanks to this new automated manufacturing machine, the customer can keep up with demand, lower costs, and know their products are made right the first time.
A: A custom wick insertion machine is a specialized piece of equipment designed to insert wicks into products—such as fragrance diffusers—at high speed and precision. In consumer product manufacturing, this type of machine ensures consistent quality, reduces manual labor, and helps meet high production demands.
A: An automatic wick inserter feeds, positions, and inserts wicks without manual handling, significantly increasing production speed. It performs high-speed placement which reduces errors, minimizes waste, and supports continuous operation in an automated assembly environment.
A: An automated manufacturing machine, like this wick assembly machine, is designed to perform multiple tasks without manual intervention. It integrates feeders, sensors, and servo-driven movements to streamline production, maintain accuracy, and meet OSHA safety standards while improving throughput.
A: An automated assembly machine uses sensors and automated rejection systems to verify correct part placement and remove defective items before they leave the production line. In the case of this automated wick assembly machine, the process guarantees that only properly assembled wicks move forward, ensuring product quality and reducing waste.
A: Automated assembly systems enable manufacturers to produce large volumes quickly and consistently while maintaining strict quality standards. For example, this automated wick assembly machine can produce 140 parts per minute, helping this customer meet demand, reduce labor costs, and stay competitive.
