NDA Protected Application
Automated 2K Filter Encapsulation
Executive Overview
Kirkco engineered a fully automated two-component adhesive encapsulation architecture to support high-volume production of precision filter assemblies. The system replaced manual encapsulation with a robot-integrated dosing cell, enabling consistent quality, reduced unit costs, and scalable production capacity.
Business & Production Drivers
A newly introduced filter design experienced rapid market adoption, driving a sharp increase in production volume. Manual encapsulation methods were no longer sufficient to maintain delivery readiness, process consistency, or cost control. Automation was required to stabilize quality while reducing labor dependency.
Process Requirements
The application demanded precise volumetric dosing of a specialty adhesive used to bond filter media to housings. Narrow tolerances, short cycle times, and repeatable shot accuracy were critical to ensure long-term filter durability and performance.
System Architecture
The solution consists of a robot-integrated automation cell paired with a modular, servo-driven two-component dosing system. The metering units are configured for shot-based operation and mounted close to the application point to minimize hose length and improve response time.
Controls & Precision
A closed-loop control architecture governs the dosing process, delivering highly repeatable shot volumes across all cycles. The modular design allows flexible configuration of mixing ratios and supports processing of abrasive or demanding adhesive chemistries.
Validation & Commissioning
Extensive pilot trials were conducted to validate material behavior, dosing parameters, and cycle performance prior to production release. Following successful testing, the system was delivered as a turnkey solution, including commissioning and operator training.
Operational Outcomes
After commissioning, the automated encapsulation process enabled high-output production with maximum process reliability. Material consumption was reduced through precise dosing, manual handling was minimized, and overall unit costs decreased measurably.
Scalability & Future Expansion
The modular architecture was intentionally designed to support future throughput increases and system expansion, ensuring long-term alignment with evolving production demands.
Adhesives & SealantsTwo-Component Adhesive Metering & Mixing Systems