Morlock´s project management goes beyond the traditional steps – system design, procurement, build, debug, factory acceptance testing and customer sign off.
Our process also ensures two key foundational goals are achieved:
Deep Expertise in Pad Print Automation
Learn more about our semi- and full-automation expertise, project management and market-specific automation experience.
Our Expertise
Morlock is widely viewed as an industry leader in pad printing automation. We have over four decades of experience building hundreds of automated pad printing solutions. Our expertise spans from simple semi-automated options to highly complex automations.
Our robust project management and deep market-specific expertise further establish Morlock as an industry-leader in pad printing automation.
Benefits
Automating a pad printing line provides:
Increased
-Line speeds
-Output/productivity
-Safety
-Consistency/repeatability
Decreased
-Man power
-Reject/scrap rates
-Factory lead times
Superior Project Management
Needs Analysis, Superior Design & Proactive Communication
Needs Analysis
The best possible solution is identified for each unique application
Superior System Design
Made possible by cutting-edge tools together with expert engineering
Needs Analysis
Morlock engineers are skilled in analyzing a range of factors in order to present the best possible solution for a particular product decorating challenge. Our engineers carefully review a range of considerations including:
- Image size & complexity
- Substrate characteristics
- Required production speed & volumes
- Production environment
- Safety requirements
- Need for pre- & post-treatments
- Compliance/validation requirements
- Customer engineering skill level
- Application performance requirements & environment
Superior System Design & Build
Our team of mechanical, electrical, control engineering and parts handling experts work to design a precision solution for each unique application. Whether the automation is big or small – the unmatched expertise of our team combined with our investment in cutting-edge technologies allow us to design systems with market-leading precision and efficiency.
Listening
The Foundation for Success
Semi-automated systems
Semi-automated systems are ideal for low volume, cost-effective production. Typically, the operator loads the part manually and our system performs any required pre-treatment, decorates the part, performs any post-treatment and vision inspection required, and brings the part back to the operator for unload.
Common Elements:
| Element | Description |
| Part Loading | Manual, operator loading onto a nested fixture. Part presence sensors may be incorporated for automated verification. |
| Safety | Full hard guarding around the system and safety light curtains are typically used. |
| Part Nesting Fixtures | Part fits into the precision-designed nesting fixtures. Depending on the requirements, rotating fixtures or vacuum may be incorporated. |
| Transport | Multi-position dial tables or linear slides may be utilized depending on the system configuration. |
| Printers | 1 or more standard pad printers may be incorporated based on the decoration requirements. |
| Treatment | Pre-treatment and/or post-treatment systems may be incorporated based on the application requirements. |
| Vision Inspection | A custom-developed vision inspection system may be incorporated along with automated accept/reject stations. |
Full Automation
Fully-automated systems automate pad printing decoration processes on your manufacturing line. Parts are typically loaded automatically into our system, which properly orients the parts, performs any required pre-treatment, decorates the part, performs any post-treatment and vision inspection required, and offloads the parts to the next system.
Common Elements:
| Element | Description |
| Part Loading | Automated, typically into a bowl-feeder. Part presence sensors are incorporated for automated verification for presence and orientation. |
| Safety | Full hard guarding around the system, safety light curtains and safety laser scanners are typically used. |
| Part Nesting Fixtures | Part to be decorated fits into the precision-designed nesting fixtures. Depending on the requirements, rotating fixtures or vacuum may be incorporated. |
| Transport | Multi-position dial tables or linear slides may be utilized depending on the system configuration. |
| Printers | 1 or more standard pad printers may be incorporated based on the decoration requirements. |
| Treatment | Pre-treatment and/or post-treatment systems may be incorporated based on the application requirements. |
| Vision Inspection | A custom-developed vision inspection system may be incorporated along with automated accept/reject stations. |
Market Specific Expertise
Over the past 40 years, Morlock has developed particularly deep expertise in automations for medical, coin, automotive and appliance applications. In addition to the experience gained completing hundreds of automations in these markets, we offer:
Medical
- Deep familiarity with the medical product production process -from molding to assembly to drug application to packaging, decoration and beyond
- Comprehensive validation & documentation service (in CFR11, IQ/OQ/PQ and others) with GAMP processes
Coins
- Deep familiarity with finishing requirements for coins and mints
- Excellent relationships with leading coin suppliers
Automotive
- Deep familiarity with interior, exterior, dashboard and underhood decoration challenges
Appliances
- Relationships with major OEMs
- Deep familiarity with the demanding environments that the appliance products face, such as extreme heat, cold, and chemical exposure.
How can we help you with your pad printing automation challenge?
We would love to hear from you.