Watch Dartronics Engineers in Action:

In the featured video, you’ll get a behind-the-scenes view of our engineering team preparing a custom-built Pack3000 print-and-apply labeling system for Factory Acceptance Testing (FAT). It’s not enough to say our machines are reliable—we show it, every step of the way.

Video Breakdown:

Led by President Ken Darrow and Engineering Project Manager Naveen Nagarajan, our in-house engineers are completing final checks on a high-speed labeling system designed for real-world production demands. This is a key phase in our FAT process, where every component is put to the test.

Here’s what’s happening in each stage:

Product Handling

Sample cartons move through a custom-designed conveyor system, engineered for precise spacing, alignment, and speed. Reliable product flow is critical for accurate labeling and inspection—so this is tested extensively.

Label Printing & Application

Using an industrial print engine, the system prints labels on demand and applies them using a precision tamp arm. Engineers inspect every detail—label accuracy, adhesion, placement, and readability—under production-like conditions.

Vision Inspection

Vision cameras verify each barcode’s presence, orientation, and legibility. This automated inspection step ensures that labeling meets all compliance and quality standards before the system is shipped.

Real-Time Engineering Adjustments

As the video shows, our engineers make live adjustments to speed, alignment, sensor calibration, and print timing. This ability to quickly tweak performance on the fly is only possible because we build and test every system in-house.

Why Factory Acceptance Testing (FAT) Matters

Factory Acceptance Testing isn’t just a box to check—it’s our final seal of approval before a system is shipped. FAT confirms that:

• The system meets or exceeds all customer specs
• All components function seamlessly together
• The machine is production-ready and operator-friendly
• Customers get a smooth, surprise-free installation

Our FAT process builds customer confidence and reinforces why so many brands trust Dartronics for their automation engineering needs.

Designed In-House. Built for Real-World Use.

This project illustrates our commitment to delivering tailored automation solutions—not one-size-fits-all systems. At Dartronics, everything happens under one roof, allowing us to:

• Reduce lead times
• Maintain full control over quality
• Customize systems to meet exact operational needs
• Support our customers with hands-on engineering expertise

Whether you’re labeling cartons, printing compliance codes, or setting up a full packaging line, Dartronics Inc. provides end-to-end solutions that are engineered, tested, and proven to perform!

OUR COMPANIES

Visit our company sites that highlight specialized machinery.

The post Behind the Build: Our Engineers Test Automation System appeared first on Dartronics.

Our Dartronics Engineers created an Order Verification Labeling System for a customer who wanted to automate their labeling process that was currently being done by hand. The customer no longer wanted to manually remove cases from a pallet and place labels on their cases by hand. The customer also wanted a more efficient process to create mixed pallet orders from their labeled cases of different products. Because the current process is labor-intensive and at the same time is also prone to human error, our proposed system would both automate the look-up and labeling system while removing human error.

Our Solution:

We custom built a fully integrated barcode scanning, printing, and verification system. (See Below)

The Dartronics Proposed system function is as follows:

• • The operator manually scans a barcode on the work order.
  • This barcode is read by the PLC control system, which does a lookup via SQL in the customers’ database to find the order’s correct breakdown.
  • Data Integration Strategy will ensure that the most current data is always named with SHIPMENTID#.
  • The Dartronics solution will require a scan of SHIPMENTID# from pick ticket (barcode) to initiate the process, utilizing SQL Lookup from the PLC to the customers either MYSQL or SQL Server needs to be provided.
  • The Dartronics solution will then import either a flat txt file or CSV file to the Teklynx Sentinel server.
  • Teklynx Sentinel Server will then cross-reference the XML file provided by D3FO, looking up label data and label format to be used.
  • Teklynx Sentinel Server will then populate the correct label format.
  • The Dartronics SQL Lookup will be used to validate over/under quantities.
  • The operator places the cases from the pallet onto a motorized conveyor.
  • The cases move in front of a barcode scanner to verify the case is in order.
  • If the case is correct – the print and apply labeler will automatically apply the correct customer label for that order to the top of the case.
  • The secondary barcode scanner system will verify that a label has been placed onto the case.
  • The operator then removes the case from the conveyor and places it onto a pallet.

See the custom labeling system in action!

Order Verification Labeling System Features

Major System Components:

• • Motorized Belt Conveyor
  • Barcode Scanner Controller for database lookup
  • Reject Mechanism for incorrectly picked cases
  • Paragon Print and Apply with Sato Print Engine
  • Barcode Scanner Controller (BSC) for top label verification
  • Reject Mechanism for Missing Labels
  • Teklynx Software Package

This custom system saves time and prevents errors by eliminating unnecessary manual processes. For more info on the above project, or if you have one in mind, call and speak to our Engineers now for a free evaluation! Our expert team is here to help make your line simpler to operate, with faster speeds that will increase your ROI.  Take A Free Evaluation!. Email us at Sales@dartronics.com or Call Dartronics at +1 (800) 298-8936  for more info.

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