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VANTROLIXAutomation Engineering Request a site assessment
Established 2011 · Pune

Automation projects that pass commissioning the first time.

We design, integrate and commission robotic cells, line control and process automation for manufacturers who cannot afford a long shakedown. Fixed scope, named engineers, single point of accountability from FAT to sign-off.

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240+Cells commissioned
15 yrsMedian engineer tenure
94%On-schedule handover
4Countries served
Sectors Automotive tier 1 Pharmaceutical FMCG packaging Metals and foundry Warehousing
Capabilities

Six disciplines, one engineering team

We do not subcontract the parts that matter. Controls, robotics and safety engineering all sit in the same office in Pune, which is the only reason we can commit to fixed commissioning dates.

01

Robotic cell design and integration

Concept through to buy-off. Reach studies, cycle time simulation, gripper and EOAT design, fencing and interlocks, then on-site commissioning.

  • Material handling and machine tending
  • Welding, dispensing and deburring
  • Vision-guided pick and place
  • Collaborative cell risk assessment
02

PLC and line control

Ground-up control system design or rescue of an existing one. Structured code, documented I/O, and handover that an in-house team can actually maintain.

  • Siemens TIA, Rockwell, Mitsubishi, Beckhoff
  • Line sequencing and interlock logic
  • Legacy migration with staged cutover
  • Code standards and library development
03

SCADA, HMI and MES interfacing

Operator screens people can use on a night shift, and clean data handoff to whatever sits above the line.

  • WinCC, FactoryTalk, Ignition
  • OPC UA and MQTT data layers
  • Batch and recipe management
  • ERP and MES interface specification
04

Functional safety engineering

Risk assessment, safety function specification, PL and SIL verification, and the validation dossier that survives an audit.

  • ISO 12100 risk assessment
  • ISO 13849-1 performance level calculation
  • IEC 62061 SIL determination
  • Validation and CE technical file support
05

Retrofit and obsolescence

Extending the life of machines built before anyone here was hired, without a full line replacement and usually inside a shutdown window.

  • Drive and motion system replacement
  • Obsolete PLC migration
  • Reverse engineering of undocumented logic
  • Shutdown-window execution planning
06

Feasibility and business case

The short engagement that comes first. Whether automation is justified at your volumes, at what capital cost, and over what payback.

  • Cycle time and throughput modelling
  • Capital estimate to plus or minus 15 percent
  • Payback and sensitivity analysis
  • Make versus buy recommendation
Case studies

Three projects, described honestly

Including what went wrong. Every automation project has a difficult month, and a consultancy that claims otherwise has not run many.

Automotive tier 1

Robotic welding cell replacing a manual station on a chassis bracket line

The client was losing 11 percent of output to weld rework and could not staff the third shift. We designed a two-robot cell with a servo positioner and integrated weld monitoring, then commissioned it inside a nine-day plant shutdown.

The difficult part was fixture repeatability. The first article runs showed positional drift traced to a supplier fixture that had never been checked. We stopped, had it re-machined, and lost six days against plan. The alternative was shipping a cell that would have produced scrap for a year.

Duration7 months
Robots2 x 6-axis, 165 kg payload
Cycle time84 s to 41 s
LocationChakan, Maharashtra

Outcomes

51%Cycle time reduction
0.8%Weld rework, from 11%
19 moPayback achieved
Read the full case study
Pharmaceutical

Batch control and data integrity remediation on an oral solid dosage line

A regulatory observation flagged incomplete audit trails and manual data transcription between the granulation line and the batch record. The existing control system worked, but nothing it did was defensibly recorded.

We rewrote the batch sequencing to be recipe-driven, added electronic signature capture at the material addition steps, and built a validated interface to the site MES. The functional specification and IQ/OQ protocols were part of the deliverable, not an afterthought.

Duration11 months
StandardGAMP 5, 21 CFR Part 11
Scope4 process trains
LocationHyderabad

Outcomes

100%Manual transcription removed
0Observations on re-inspection
3.5 hrBatch record review, from 14
Read the full case study
FMCG packaging

Legacy PLC migration across six packing lines without stopping production

Six lines running a control platform that went end-of-support in 2019, with no source code and one contractor who understood the logic. The client had been quoted a full line replacement.

We reverse engineered the existing logic line by line, rebuilt it on a supported platform with proper documentation, and cut over one line per weekend shutdown across three months. Line four had an undocumented interlock that only appeared during a specific changeover, which cost us a Saturday and a half.

Duration5 months
Lines6, staged cutover
Downtime0 unplanned hours
LocationBaddi, Himachal Pradesh

Outcomes

0 hrsUnplanned downtime
72%Below line replacement quote
6Lines fully documented
Read the full case study
Engagement model

How a project runs from first visit to sign-off

The first stage is deliberately small and separately priced. If the numbers do not support automation, we say so and you have paid for a study rather than a project.

01

Site assessment

Two engineers on the floor for two days. Line observation, constraint identification, and a written finding on whether the case holds.

2 to 3 weeks
02

Concept and estimate

Layout, cycle time model, equipment specification and a capital estimate accurate to plus or minus 15 percent.

3 to 5 weeks
03

Detailed design

Mechanical, electrical and controls design, safety risk assessment, and the full bill of materials for procurement.

6 to 12 weeks
04

Build and FAT

Assembly and factory acceptance testing at our Pune workshop, with your engineers present for the buy-off.

8 to 20 weeks
05

Install and handover

Site installation, SAT, operator and maintenance training, and the documentation set. Then 12 months of defect support.

2 to 6 weeks
Platforms

What we work on

We are not tied to a single vendor. In practice the platform is usually decided by what your maintenance team already knows, and that is the right way to decide it.

Control platforms

  • Siemens S7-1500 / TIA Portal
  • Rockwell ControlLogix
  • Mitsubishi iQ-R
  • Beckhoff TwinCAT 3
  • Schneider M580

Robotics

  • FANUC
  • KUKA
  • ABB
  • Yaskawa Motoman
  • Universal Robots (cobot)

Visualisation and data

  • Siemens WinCC
  • Rockwell FactoryTalk View
  • Inductive Automation Ignition
  • OPC UA / MQTT Sparkplug
  • Historian integration

Vision and sensing

  • Cognex In-Sight
  • Keyence CV series
  • SICK safety scanners
  • Photoneo 3D
  • Load cell and torque monitoring
Functional safety

Safety engineering is a deliverable, not a checkbox at the end

Most of the automation projects we are asked to rescue have the same problem. The safety functions were added after the mechanical design was frozen, so the guarding is awkward, the operators defeat it, and the validation file does not exist.

We run the risk assessment during concept design, before the layout is committed. That is the only point at which the cheap fixes are still available.

Every cell we deliver comes with a validation dossier: the risk assessment, the safety function specification, the PL or SIL calculation with the underlying component data, and the test records proving each function performs as specified.

DeliverableStandard
Machine risk assessmentISO 12100
Safety function specificationISO 13849-1
Performance level verificationISO 13849-2
SIL determination for process safetyIEC 62061 / IEC 61508
Collaborative robot force studyISO/TS 15066
Electrical equipment of machinesIEC 60204-1
Validation and test recordsISO 13849-2 Annex
CE technical file supportMachinery Directive

Start with a site assessment.

Two engineers, two days on your floor, and a written finding on whether automation is justified at your volumes. Priced separately from any project that follows, so the recommendation is not a sales document.

Request a site assessment

Vantrolix Automation Engineering

Head officePune, India
WorkshopChakan MIDC, 1,800 sq m
Engineering staff46
Enquiriesprojects@vantrolix.example
Telephone+91 20 0000 0000
Assessment lead time3 to 4 weeks