Assembly and packaging line for razor cartridges
PIA fact check
- High-precision assembly of delicate blade units for wet shaving
- Patented multi-blade technology for stable high-speed operation
- Two high-speed transport systems for maximum production output
High-volume production under demanding manufacturing conditions
Stability in a high-performance process
For a close and safe wet shave, the quality of every single razor cartridge is crucial. In particular, the processing of extremely thin, hardened and sharpened blades places the highest demands on fully automated assembly handling, process reliability and repeat accuracy.
To meet these requirements, PIA Automation worked closely with a long-standing customer to develop another high-volume assembly line for replacement razor cartridges, successfully mastering numerous technical challenges throughout the project.
Use of patented PIA multi-blade technology
A key element of the line is PIA’s proven multi-blade stations. Blade singulation and assembly are among the most critical steps in automated razor cartridge production and demand exceptional precision and process control, particularly at high output rates.
“Our multi-blade stations are specifically engineered for high-speed applications of this kind,” explains Tim Schuller, Product Manager at PIA. “As part of this project, we further optimized the technology for both blade singulation from the magazine and precise insertion into the cartridge frame. The result is a highly stable, low-wear assembly process that ensures reliable long-term operation at maximum throughput.”
System architecture with parallel transport structure
Spanning an area of approximately 35 × 12 meters, the line integrates multiple assembly units, including six multi-blade stations, connected via two parallel high-speed transport systems developed specifically for this application. Each module is equipped with fully automated infeed and outfeed functions for the required components.
This provides a continuous material flow while enabling targeted decoupling of individual process steps. “Assembly cycles with longer cycle rates can thus be executed multiple times within the same line without reducing overall output,” says Schuller. “The workpiece carriers are distributed across several cycle-critical stations, thereby avoiding unnecessary downtime.”
Another advantage of this modular setup is its high availability during operation. Individual modules can be selectively shut down for maintenance or service without interrupting the line. As a result, the system remains operational at reduced output, minimizing maintenance-related production losses.
The final assembly and inspection processes are carried out on a Beckhoff XTS linear transport system that supports synchronized processes as well as dynamic measurement and testing procedures. The transport concept integrates end-of-line (EOL) inspection for every razor cartridge produced, using a specially developed combination of 2D cameras and 3D laser line scanners. In addition to standard vision inspection tasks, the blade extrusion angle is measured, a key quality parameter that directly influences the shaving result for the end customer.
Following the EOL tests, the system performs fully automated packaging of the cutting units. Depending on the product variant, the razor cartridges are either individually fitted with protective caps or packaged in multiples within a refill dispenser. In this way, different market requirements can be met within the same line without additional changeover time.
Project execution based on a proven partnership
With this new system, PIA Automation once again sets industry-specific standards in the high-volume assembly of delicate shaving components. The experience gained from previous projects with this long-standing customer provided a valuable foundation for the continuous refinement of individual process steps. This made it possible to fully meet the ambitious targets in terms of performance, precision, process reliability and operational safety.
“The project demonstrates how important close collaboration and a shared understanding of processes are,” emphasizes Schuller. “On this basis, we were able to implement a solution that delivers both technical and economic advantages through a flexible system concept and the use of our multi-blade stations.”
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