Creating Safer Workplaces through Industrial Automation
Safer working environment for humans is one the biggest boons of automation. Every
passing day, innovative automation systems are being created all over the world to keep
humans away from dangers. These dangers might pose an immediate risk to the life or body
parts of humans or they might be in the form of tasks which put human health at risk if they
carry out these tasks over a long term. Here is how automation can help in eliminating these

Preventing loss of life or body parts
In automotive manufacturing, press shop is one of the most accident prone areas. There are
innumerable cases where operators have lost their fingers or even hand while working with
the press machine. In fact, in one of the unfortunate accidents, a maintenance operator lost
his life while doing the routine maintenance of a press machine.
Press machines require an extremely high level of eye-hand / foot coordination. Not to
mention, the machines are absolutely unforgiving of mistakes. A single blink of an eye and
the operator can lose a precious part of his body. Press loaders and unloaders from
Cybernetik can help manufacturers keep workers away from this accident prone area and
make the workplace safer for them.

Eliminating cumbersome tasks
Certain industrial tasks need to be done and need to be done at a specific speed to continue
the production line without being interrupted. This is also necessary to achieve economies of
scale in price-sensitive markets like automotive manufacturing or FMCG products like snack
food items.
Such tasks and their speed requirements make them too cumbersome for humans. Imagine
a shop floor worker lifting and moving a 100 kg bag several times a day. It not only puts the
worker’s health and safety at risk, it also negatively affects the manufacturing line as humans
will inevitably work at reduced speed after some time. This creates a bottleneck in the
system, which can be easily and efficiently avoided through automated systems like robotic
Production of food items may not be an obviously risky or unsafe process. However, when
food items are produced on the industrial scale, it can quickly transform into a cumbersome
task. Take the example of a worker who is working in a factory that produces savoury fried
snacks and who has to deep fry the food items. He needs to work in the dangerous vicinity
of an enormous quantity of boiling oil. Besides, the fire and heat also pose the risk of
Apart from this, the highly repetitive task can quickly become a boring chore for humans.
Bored humans may or may not follow the standard procedure while doing the task. This not
only puts humans in the close vicinity of a danger, it might also lead to the production of
substandard quality food items, which again becomes a health risk for consumers. Snack
food automation helps in avoiding these risks, making human resources available for more
skilled tasks.

Keeping humans away from hazardous materials and environments
In industrial manufacturing, humans need to work with all kinds of materials. Some of them
are not safe for humans and might put their health at risk. For example, there might be
hazardous chemicals, which need to be packed in bags. Exposing humans to these
chemicals might put their health at risk in the long term or sometimes even in the short term.
Automatic bagging systems help in eliminating this risk.

In certain cutting tasks, the dust produced during the process is harmful for humans. It
becomes a health risk for them when it enters their eyes, mouth or nose. To prevent this,
completely automated systems are designed, which are then covered with a canopy so that
the dust does not get spread into the atmosphere.
There are several such examples of automation systems that help prevent or reduce safety
risks to humans in different industries. Cybernetik can work with you to design and create
automation systems to enhance safety in your industry. Get in touch with us to know more.
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Innovative Technique in Agro Processing: Supercritical Fluid Extraction (SCFE)

Innovations in food processing industry are comparatively slow, as safety and quality are always the primary concerns. Supercritical Fluid Extraction System from Cybernetik fulfills these criteria and provides a safe and profitable solution for the agro-processing industry. What is Supercritical Fluid Extraction process? SCFE is one of the recent techniques used for agro processing. It is used primarily for decaffeination of tea / coffee, fractionation of polymeric materials, and extraction of oils, oleoresins, flavours, fats, spices and many other ingredients. When a substance is heated and pressurised above its critical point, it transforms into its supercritical state, where it is neither liquid nor gas. In this particular state, a substance can effuse through solids like a gas and dissolve materials like a liquid. Thus, it becomes a powerful medium for extraction of ingredients from raw materials.  Why CO2 is a preferred fluid for SCFE process? Carbon dioxide in its supercritical state is non-toxic, non-flammable and chemically inert. It also provides higher extraction efficiency and is ideal for high value extracts. There is no need for solvent removal. As CO2 is considered safe for humans, it is a preferred supercritical fluid in agro and food processing. Why use SCFE system from Cybernetik? Cybernetik’s SCFE system provides higher extraction efficiency, high product purity, consistent product quality and prolonged product shelf life. It is easy to clean and maintain and significantly reduces the operating costs. The system uses USFDA approved process for extraction of ingredients from organic raw materials in agro-processing industry. The system consists of high pressure and heating system, where liquid CO2 is transformed into supercritical CO2. The supercritical CO2 is mixed with the raw material in the extraction vessel. The mixture is further transported into gas-liquid separation chamber, where supercritical CO2 transforms into gas and is easily separated from the extract. This gas CO2 can be conveniently reused for further process. Using Cybernetik SCFE systems can offer several other benefits in your industry. Know more about SCFE system and other agro-processing solutions from Cybernetik.For further information, contact our representatives.

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Factory Acceptance Testing (FAT) - An Essential for Optimum Delivery

Delivering quality and exceeding the expectations of our clients is always a requisite at Cybernetik. Factory Acceptance Testing or FAT is one of the project milestones that helps us meet our goals and ensure smooth functionality of the system through its entire lifecycle. Systems that go through rigorous FAT enable our clients to achieve optimum productivity and be the frontrunners in their respective industry. What is FAT?Prior to the delivery and shipment of any automation system, we build the entire system at Cybernetik, just as it would have been built at the client’s place and perform a comprehensive scrutiny, also known as Factory Acceptance Testing or FAT.  This scrutiny includes checking the system for a number of factors like Functionality, SLA adherence, Legal & Compliance accuracy, P&ID and quality certifications. Going further, at Cybernetik we also prepare the system for Key Performance Indicators (KPIs) such as production rate (cycle time), process flow, user interface, workmanship and safety. When is FAT performed?  FAT is performed before we dispatch the system from Cybernetik. It helps us ensure quality and safety of the system. It also saves on time and cost. Issues can be identified and rectified while the system is still in our factory. This reduces the initial hassles while setting up the system at the client’s place and reduces the time to make it run smoothly and to its full capacity. In addition, it gives client a clear idea of the physical layout and if there is a need for alterations and reconfigurations, they can be implemented prior to the delivery. Who should be present during FAT?To ensure the success of FAT, we recommend the presence of personnel from client’s side on the shop floor. The personnel could be Project Managers, Operators, Plant Engineers and Maintenance Engineers. This helps everyone understand the environment where the system is being tested enabling better troubleshooting in case of breakdowns during run-time. Why is FAT important?FAT helps identify non-conformities in the system while the system is still at Cybernetik, so that problems can be addressed before installation of the system. This offers more flexibility to our technical experts for providing optimal solutions, without affecting the project timelines. FAT also eliminates ambiguity around the KPIs set for the equipment. Though Cybernetik incurs considerable costs simulating real-time shop environment for the system to be appropriately evaluated, this lowers the risk of breakdowns during shop time as well as the need for repetitive servicing. At Cybernetik, FAT is not billed to the client separately, as it is included in the scope of delivery established earlier. We clarify and lay down the requirements and measures that will compose a customised FAT, and these are carefully implemented to ensure the success of FAT. Just like before delivering any product, the manufacturer checks it for quality, FAT is performed before the shipment of automation equipment to ensure its quality standards and full functionality. It is also important for ensuring safety of equipment and personnel. After all, creating safer workplaces is one of the most important aspects of industrial automation. Click here to read more.FAT is a standard procedure that helps us deliver robust and consistent results and enables our clients to gain optimal benefits from Cybernetik systems. Contact us to know more about how you can optimize your processes through automation systems from Cybernetik.

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Six-Axis Robots: What are they? Their Benefits & Integration

Robotic manufacturers have designed and developed several different types of robots to fulfill the automation needs of various industries. The standard Six-Axis Robot is one of the most widely used among them. Axis: The Facilitator of Robot’s Movement A major factor in an industrial robot is the number of axes it has. Each axis allows a degree of flexibility and enables a robot to reach to the desired point. The six axis robot, can move in three dimensional space across x, y and z planes. Different types of robots are suitable for different industrial applications. Certain tasks like part picking, material handling, sorting, stacking and palletising can be accomplished with fewer axes. Robots with fewer axes provide more stability, are simple to operate and maintain and also reduce energy consumption and overall cost. Certain other tasks like assembly may require a robot with as many as 15 axes, where more flexibility is required. But these robots also tend to be more expensive. Six-Axis Robots Most of the industrial applications can be carried out with the help of the standard six-axis robots, also called articulated robots. These provide a good combination of power, stability, flexibility and value for investment. Here is how each axis allows flexibility to the robotic arm. Axis 1: Located at the base of the robot, it allows the robot to move in the range of 180 degrees from left to right. Axis 2: Facilitates the forward and backward movement of the robot’s lower arm. Axis 3: Allows the robot’s upper arm to move in upward and downward direction. Axis 4: Known as the wrist roll, this axis rotates robot’s upper arm and working together with axis 5 positions the end effector. Axis 5: Allows the robot’s wrist to move in upward and downward direction with pitch movement and move from side to side with yaw movement. Axis 6: This is the robot’s wrist and enables it to rotate freely in both left and right directions. Benefits  Optimum flexibility Easy programming Multiple mounting options Easy maintenance and repairing Adaptability  Integration Cybernetik offers complete integration of all types of six-axis robots from the well-known manufacturers like ABB, Kuka and Yaskawa. There are many different types of six-axis robots, both large and small. According to the specific requirements of the task, different factors need to be determined like size, speed and payload. Cybernetik offers end-to-end assistance in this regard from selecting the right robot to installation and after-sales support. Contact us to know more. To understand the benefits of robotic automation over SPMs (Special Purpose Machines), click here.

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Cybernetik Technologies is an Indian industrial automation company that designs, builds and installs turnkey automation systems to address the material handling and processing needs of the agro process, food, automotive and environment sectors. Our expertise lies in providing innovative solutions for conveying, processing, robotic handling and end-of- line packaging. We are a single source solution for all automation requirements by providing services ranging from concept generation to installation, commissioning and after-sales support.

Copyright 2016 | Cybernetik Technologies Pvt. Ltd.