Exploring automation and robotics
Automation and Robotics: Driving Industrial Performance at Mora Group
Automation and robotics continue to profoundly transform the industrial landscape. At Mora Group, these technologies are embedded at the heart of our production lines to ensure precision, performance, and cleanroom compliance. Through the insights of Christophe Basset, discover how automation has become a strategic asset for optimizing processes in the plastic injection molding industry.
Hello Christophe, could you briefly introduce yourself?
I’m Christophe Basset, Industrial Methods Manager at Mora Group since 2006. My role is to design, define, and implement all the processes and industrial resources required for the production of injected parts — except for the molds. I oversee the definition of production lines, injection presses, and associated robots, as well as the creation of controlled atmosphere areas (ISO 7 and ISO 8). I’m also involved in integrating post-injection assembly and inspection machines. My mission is to support Mora Group in developing and implementing automation and robotics solutions tailored to our clients’ needs and the demands of their markets.
Christophe, can you explain the difference between robotization and automation? What does each term actually mean?
We can distinguish between automation and robotization. Automation often involves robotics, but not always. Some steps, such as packaging, can be fully automated without any direct use of robots.
In our field of plastic injection molding, the first step after injection is to unload the molded parts. This can, of course, be done using dedicated robots, but also through automatic systems that don’t rely on robotics. For example, we use counting and packaging systems combined with conveyors, which allow us to efficiently manage the continuous production flow.
What are the concrete benefits of automation in the plastic injection molding industry?
One of the main benefits of automation is the optimization of production cycles and the associated workforce. Beyond productivity, it also improves reliability and quality. For example, by automating the counting of parts, Mora Group ensures that each package contains the exact number of units required. Another key advantage is the elimination of direct contact between molded parts and operators’ hands during final packaging. This level of control significantly reduces the risk of product contamination.
Finally, this evolution has also improved ergonomics for operators. Previously, they had to manually place boxes on scales, monitor the filling process, and replace containers once they were full. This repetitive and physically demanding task has been replaced by automated systems equipped with conveyors and in-line weighing. Operators are now freed from these time-consuming operations and can focus on higher value-added tasks.
What types of robots are used at Mora Group, and what are their main functions?
Coming back to robotics, we use several different types of robots:
- So-called “cartesian” robots
Particularly for productions intended for the automotive sector. These robots operate on three axes (X, Y, and Z), similar to a mathematical coordinate system, and are the most common type used in the plastics industry. Their arm moves up and down along the vertical axis, while a horizontal beam allows them to travel and perform part pick-and-place operations.
Although this system can be bulky, it allows for extended reach and is perfectly suited to managing multiple part references. Another advantage is its ability to handle heavy loads.
- High-speed side-entry robots
These robots are used for productions with very short cycle times. Their purpose is to minimize the robot’s intervention time inside the mold and avoid impacting the overall injection cycle duration.
- 6-axis robots
In France, Mora Group primarily deploys 6-axis robots, especially for medical applications. These robots offer multiple advantages:
- Their compact design makes them particularly well-suited for cleanrooms, where every cubic meter must be optimized to minimize the air volume handled by filtration systems.
- They also stand out for their low particle emission and ease of cleaning. Some models used by Mora Group can operate in environments up to ISO Class 5, ensuring full compliance with the stringent standards of the medical and pharmaceutical industries.
- Most importantly, they provide greater freedom of movement, making them ideal for post-injection operations.
Today, the French site in Chambost-Allières is equipped with 6-axis robots used for part unloading as well as specific tasks such as vision-based quality control, packaging, and pad printing. This versatility enables cleanroom integration of finishing and customization stages while maintaining the highest standards of cleanliness and traceability.
What criteria guide your choices between the different types of robots and automation solutions?
The systems implemented to optimize existing production lines are primarily driven by productivity gains, balanced against the cost of the required investment.
When it comes to new projects, installations are always designed around the specific characteristics of each product. The choice depends on multiple parameters such as the associated machine, type of production, cycle time, number of part references to manage, and the operations to be performed on the product (assembly, sorting, inspection, etc.). Robots provide the flexibility needed to adapt to these requirements and ensure solutions that are perfectly aligned with each product’s specifications.
For each new project, and according to the specific needs of the client and the product, Mora Group develops complete automatic or semi-automatic assembly lines, as well as special-purpose machines — particularly for assembling components for the automotive industry at our Portuguese and Romanian sites. These dedicated systems ensure both assembly reliability and strict adherence to the cycle times and cost requirements demanded by the sector.
How are robots redefining industrial performance at Mora Group?
Mora Group continuously upgrades its robot fleet and automated lines to meet client needs and adapt to upcoming projects, always with a focus on staying at the forefront of existing technologies.
The company remains attentive to emerging innovations, particularly artificial intelligence, which is already integrated into our camera-based inspection systems. These systems automatically verify part quality at the end of the injection process, offering unmatched reliability and speed. AI enhances inspection accuracy, reduces human error, and ensures consistent batch compliance.
Data processing software applied to injection molding already enables continuous self-diagnosis of machines. These advancements are paving the way for more predictive industrial processes — capable of anticipating deviations and adjusting production parameters in real time.
Artificial intelligence already plays, and will increasingly play, a key role in automation — and robots will undoubtedly be part of that evolution.
To be continued…
