Custom Automation
We deliver turnkey custom automation solutions – from initial concept through commissioning – so that your factory operates more efficiently, more safely, and to the highest standards.
Complete Production Line Design
Designing a production line is a complex process covering everything from the shop-floor layout and machine selection to full automation integration. The goal is to create a line tailored to a specific facility—one that maximizes throughput and quality while maintaining strict safety standards.
Our engineers combine expertise in mechanics, robotics, and controls to deliver “turnkey” production lines: from facility layout and mechanical structures to PLC/SCADA software and safety systems. Thanks to years of experience across sectors—from automotive and FMCG to railway and electronics—each project is customized to industry specifics. We design lines ranging from simple to highly advanced, always emphasizing reliability, efficiency, and compliance with industrial norms.
Custom automation often involves designing specialized conveyor lines and integrating various machines into a cohesive production system. These systems are configured around the unique needs of each factory, ensuring smooth material flow and synchronized operations. By tailoring every component—from conveyors to robotic stations—the entire line can achieve peak efficiency with minimal downtime. Careful layout planning and controls integration mean even complex processes can be automated to improve productivity and quality.
Our Offer
Our custom automation services include:
- Concept & layout design – We analyze your production process and prepare a preliminary concept of the line, developing a station layout and material flow that account for space constraints and ergonomics.
- Mechanical design & equipment selection – We develop a detailed mechanical design covering workstations, conveyors, feeders, and other machinery, selecting proven components for reliability.
- Automation & control systems – We design PLC control systems, HMI/SCADA interfaces, and integrate industrial robots wherever they can boost efficiency. Our automation solutions enable 24/7 operation, ensuring consistent quality and minimizing human error.
- Integration, commissioning & training – We supervise on-site assembly and start-up of the line to ensure a smooth implementation with minimal disruption to your ongoing operations. As part of handover, we provide training so your team can safely operate and maintain the new system.
- Technical documentation & certification – We deliver complete project documentation (electrical schematics, 3D drawings, manuals, parts lists, risk assessments) and handle compliance certification. By addressing safety requirements and standards from the start, we ensure the entire system meets all applicable regulations (e.g. CE marking).
- Existing line optimizations & upgrades – We also analyze and improve running production lines. We identify areas for improvement—whether it’s increasing throughput, cutting operating costs, or adapting equipment to new products or new regulations—and implement solutions to modernize your line without needing to rebuild from scratch.
Our Approach to Custom Automation
In complex automation projects, success isn’t just about cutting-edge technology—it also relies on meticulous planning and close collaboration. At Engineering Shield, our approach ensures each custom automation project is delivered reliably and meets your real-world production goals. We focus on three core aspects:
Engineering diligence & planning – Every project begins with a methodical, in-depth analysis of your needs and technical conditions. We prepare detailed design requirements and a clear work schedule so that both our team and the client understand each stage and the expected results. Before full implementation, we validate key concepts (for example, through simulations or prototypes) to make sure the proposed solutions are feasible and cost-effective. If we encounter limitations or risks, we communicate them openly—it’s better to adjust the plan early than to promise unrealistic outcomes.
Transparent collaboration & flexibility
We believe in a close partnership with the client at every stage of the project. Communication is open and transparent: you’re kept up-to-date on progress, we make key decisions together, and any changes are discussed in real time. Our approach is flexible—we can adjust the project scope or pace to accommodate evolving requirements or budget constraints. No matter the scale of the task—whether it’s upgrading a single workstation or designing an entire new line—we assign the appropriate team and resources to meet the challenge. You can count on our technical guidance and honest feedback at every step, building trust and confidence that our shared goal will be achieved.
Custom Automation – Services & Key Benefits
| Service area | What we do | Key benefits |
|---|---|---|
| Concept & Layout Design | Process analysis, line concept, 2D/3D layout preparation | • Tailored to your production goals and space constraints• Optimized material flow and ergonomics• Clear investment roadmap |
| Mechanical Design & Equipment Selection | Detailed mechanical design of stations, conveyors, feeders, and structures | • High reliability and operator safety• Standardized components for easy maintenance• Improved ergonomics and lower failure risk |
| Automation & Robotics | PLC programming, HMI/SCADA design, robot and sensor integration | • Increased throughput and quality consistency• Continuous 24/7 operation• Smart diagnostics and quick fault recovery |
| Integration & Commissioning | Installation, wiring, software setup, line start-up, training | • Faster commissioning and full readiness• Minimal production downtime• One responsible partner for the entire project |
| Documentation & Compliance | Technical files, CE marking, risk assessment, manuals | • Complete documentation package• CE/ISO compliance and audit readiness• Simplified maintenance and modification |
| Modernizations & Optimizations | Upgrading existing lines, retrofitting, process improvement | • Higher performance without new machines• Reduced operating costs and energy use• Improved safety and compliance with regulations |
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Process comes first
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Pilot before big investment
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No empty promises
- Process comes first – We always start with a solid analysis of your value stream and production data before drawing the first layout. This way, the line is truly designed to fit your factory’s needs, not the other way around.
- Pilot before big investment – If a process is new or not well-defined, we build a pilot station or mock-up to verify the technology and ergonomics. By testing solutions in a pre-production environment, we minimize risk and avoid costly surprises during full-scale implementation.
- No empty promises – We establish the project timeline and budget together and stick to them. If something isn’t achievable, we’ll say so up front. We would rather decline a project than promise a “miracle” and end up wasting everyone’s time and resources.
Experience & continuous improvement – Dozens of completed projects have taught us that in industry, practical solutions and safety are paramount. In designing automated lines, we emphasize proven technologies (and when introducing new tech, we rigorously test it first), while also keeping an eye on emerging trends to evaluate their benefit for your case. Every project undergoes multi-stage quality control—internal design reviews, risk analyses, and on-site acceptance tests—to ensure the final result meets both our high standards and your expectations.
FAQ: Custom Automation
We begin with a concept workshop involving your production and maintenance team. We map out the process and define the key parameters. If any data are missing, we’ll build a pilot mock-up to validate the assumptions before you invest in a full production line.
A simple assembly workstation can be delivered in about 4–6 months. A full line with multiple stations, automation, and testing typically takes 12–36 months. We break the timeline into stages from the start, so you’ll know when each milestone will occur and what decisions will be needed at each step.
There are often many paths to the goal, so a fixed-price model isn’t always best when a project has many unknowns – such quotes include contingencies for risk. That’s why we often start with a preliminary design phase to know exactly what we’re pricing. Sometimes, to determine the exact cost of a solution, it needs to be tested in a prototype phase. If you already have a solid process specification and only need integration, then the cost estimation is much easier and more predictable.
You receive a full documentation package (2D/3D layouts, electrical schematics, parts lists, operation manuals, risk assessments) and training for your operators and maintenance staff. In the first weeks after commissioning, we also typically provide on-site support for an agreed period to assist with any teething issues.
Yes, as long as they can pass a technical and safety audit. We will check their mechanical condition, ability to integrate with the new control system, and the cost of necessary upgrades. If it’s feasible and cost-effective, we’ll include your existing equipment in the new layout. If not, significant modifications (or replacing the equipment) may be required.
Get in touch!
We’re happy to answer your questions and discuss how custom automation can benefit your production.