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Automatic line for production of plastic injection

molded components


Robotic automatic line for the realization of 5 models of molded and co-molded gears by using the plastic injection molding process. ABB IRB2600 robot manages the loading/unloading process from the Battenfeld 110T injection molder which communicates with the line via the EUROMAP67 communication protocol. Two ABB IRC910SC robots manage components finishing, quality control and packaging operations.

Star Automation took care of the entire construction of the line, from the electrical and pneumatic design and construction, to the software development, up to the mechanical design and construction which took place thanks to the collaboration with Fimir Srl and UTP Srl.

The line includes 2 vibratory feeders for the singolarization of the components, a pneumo-hydraulic shear for the removal of the sprues after moulding, a rotary table for the finishing operations and quality control of the components which takes place via vision systems with Omron FH cameras.

The plant was installed at the headquarters of FAIST Components SpA in Montone (PG).


Robot, PLC and HMI programming for F-Latch foaming and packaging robotic line


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Programming for F-Latch production line has involved the following stations:

- Robotic station for F-latch loading from production line

- 2 robotic stations of plasma etching

- 2 robotic stations of foaming

- Robotic station of laser marking

- Robotic station for F-latch unloading in the oven to perform the foam curing

- Robotic station for scrap unloading

- Packaging station

Software programming has involved:

- 5 ABB IRB 2600 robots

- Omron NX1 PLC

- 4 Omron NB7W HMI

- Festo electric axis

- 2 Keyence laser marker

- Automator marker

- Zebra printer

- Cognex QR code

The work was carried out at Magna Mechatronics in Guasticce (LI).

Retrofit on robotic palletizing cell



Software and mechanical revamping of a robotic palletizing cell.

​Laser sensors were installed on the conveyor belt to measure carton heights in order to stack cartons with different heights. Boxes centering systems were installed on the end-of-line conveyor belt to ensure the robot a repeatable loading of boxes.

The software programming of Yaskawa MPL 160 II and Omron CJ1M PLC was performed.

The new patented flexible robotic palletizing system is able to handle boxes - even of different formats - quickly and reliably, avoiding downtime of the lines, optimizing space, reducing packaging waste and transportation costs, and thus increasing plant efficiency and productivity.

Just now saves more than 50.000 cartons/year thanks to the new algorithm.

The work was carried out at the logistics center of Just Italia (VR).


Robotic cell for CNC machine loading



Study and design of robotic cell for CNC machine automated loading.

Thanks to a highly-precise vision system the costumer is able to easily move the robotic cell from one CNC machine to another.

The management software allows to load different components in the cell and to handle them at the same time.

PLC and HMI software programming for 4.0 buffering cell



Siemens S7-1500 PLC and Siemens HMI software programming for autonomous loading and unloading of semiaxles.

The plant consists of a 4.0 fully automated cell for production of semiaxles in automotive field.


Star Automation developed the software programming for both quality control station and buffering station. A series of robots interact with the buffer station to carry out the whole process production.

The work was carried out at GKN Driveline factory in Campi Bisenzio (FI).


Robot software programming for CNC machine loading



ABB robot programming for two CNC machines automatic loading.

Thanks to a Cognex vision system the robot is able to identify the blanks to load.

The managing of the boxes for blanks and finished products is completely automated.

The work was carried out at Pierburg Pump Technology factory in Leghorn (LI).


Robot software programming for injection moulder loading



ABB robot software programming for automated production of injectors with autonomous loading and unloading of workpiece into injection moulding machine.

The work was carried out at Continental factory in Fauglia (LI).


Service on a welding robotic cell



ABB robot programming on already existing plant.


A welding cell is loaded and the finished products (semiaxles) are pallettized.

The work was carried out at GKN Driveline factory in Campi Bisenzio (FI).


Robot software programming for leather parts bonding



Yaskawa robot programming for bonding, handling and moving applications of leather parts for wallet realization.

Robot software programming for automated screwing line



Two ABB robot programming for automated screwing line of gearboxes.


The work was carried out at Bonfiglioli factory in Forlì (FC).


Off-line robot path acquisition



We develop applications to allow operators to program robot paths without using teach pendant or without knowing programming languange by using 3D laser scanner o microscribe.

Dual-arm robot software programming



Robot Yaskawa SDA10 software programming for pick&place operations between a trimming line and a injection moulding rotary table for shoe industry.

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