Vacuum automation improves production efficiency in laundry manufacturing

The application

High volume laundry appliance manufacturing relies on efficient, repeatable processes to meet production targets and maintain quality. Injection molding operations must operate reliably at speed, with consistent part handling to avoid downstream bottlenecks in inspection and packaging.

For Alliance Laundry Systems, increasing demand exposed limitations in an existing molding process that relied heavily on manual intervention. Labor shortages and frequent downtime made it difficult to maintain output levels, prompting the need for a more automated and reliable handling solution.

The challenge: increasing demand and operational strain

Alliance Laundry Systems needed to improve production throughput while reducing dependency on manual labor across its injection molding operations. Key challenges included:

• Inconsistent unloading performance at molding machines

• Frequent downtime caused by labor availability and manual handling variability

• Limited capacity to scale production without adding headcount

• Manual quality checks and part orientation stages slowing downstream processes

The team required a solution that could increase efficiency and uptime without compromising part quality or adding unnecessary complexity to maintenance and operation.

The solution: custom vacuum End of Arm Tooling (EOAT)

Working closely with the Alliance Laundry Systems team, we developed a custom designed vacuum End of Arm Tooling (EOAT) solution tailored to the application and automation goals.

The EOAT was engineered to improve unloading efficiency directly at the injection molding machines, delivering consistent, repeatable part handling at higher speeds. Integrated automated quality control devices verified parts before transfer, removing the need for manual inspection steps and additional staffing.

The system also introduced repeatable handling techniques that pre‑staged parts for operators, minimizing re‑orientation time during downstream packaging. Throughout the design, cost, quality and maintenance simplicity were kept in focus to ensure long‑term operational value.

The result: higher throughput and improved workflows

The custom vacuum automation solution delivered measurable improvements across production performance, cost and operator experience:

• Increased machine throughput through automated, consistent unloading

• Improved uptime by reducing reliance on manual intervention

• More consistent part handling with reduced cycle variation

• Lower labor burden, supporting future insourcing initiatives

• Improved operator workflows, allowing teams to focus on higher value maintenance and process improvement tasks

• Reduced downstream handling time through reliable part staging and placement

By stabilizing a core production process, Alliance Laundry Systems increased output while reducing operational strain and improving overall manufacturing efficiency.

Automation support for industrial appliance manufacturing

This project highlights how custom vacuum automation and End of Arm Tooling solutions can support high volume appliance manufacturing environments. By combining application insight with adaptable automation technologies, we help manufacturers improve throughput, reduce downtime and create more resilient production processes.

Find out more about our automation and custom solutions for industrial manufacturing.