How Automation is Driving Efficiency and Precision at Wisconsin Plastics, Inc.

At Wisconsin Plastics, Inc. (WPI), innovation doesn’t end at the molding machine, it’s woven into every part of how we work. Our commitment to quality, efficiency, and continuous improvement has fueled strategic investments in advanced automation systems that are reshaping how we manufacture, assemble, and inspect products across medical, industrial, and consumer markets.

From robotics and automated decorating to AI-powered vision systems, automation helps us deliver better products, faster, with the consistency our customers expect. Here’s a closer look at how WPI is elevating manufacturing through smart automation.

Gusmer Pod Plug Cell

Industry: Medical
Function: Automatically feeds and shrink-wraps six molded pod plugs in a clean, consistent stack.

Meeting the high volume demands of medical manufacturing requires precision, throughput, and repeatability. Our automated Gusmer Pod Plug Cell delivers all three. By removing manual steps, we’ve:

• Increased production capacity
• Reduced overall labor and material costs
• Ensured consistent, repeatable output

This cell gives WPI a competitive edge during quoting and delivers peace of mind to customers who rely on unwavering quality.

OMT Lid / Hole Saw Case Lid Hot Stamping

This automated hot stamping process creates clean, white markings on tool case lids and similar components; markings that need to be crisp, durable, and highly consistent.

Before automation:

• A 45-second cycle molded four parts
• Each part required manual de-gating
• Operators completed the hot stamping process by hand

After automation:

• The same 45 seconds now molds four parts, automatically de-gates them, and hot stamps all four—completely hands-free

The impact is significant: faster cycles, consistent quality, and reduced labor, all while maintaining strict brand and performance standards.

OMT Lid Sticker Assembly

This automation system applies both front and back labels with precise alignment to ensure every part receives consistent branding and identification. A built-in vision system performs placement checks and verifies that required components are present.

The benefits include improved accuracy, fewer defects, and increased overall efficiency.

Fanuc 6 axis robot

One of our most advanced systems centers around a yellow robot equipped with AI-driven vision. This powerhouse automation:

• Trims runners with precision
• Places each part onto cooling fixtures for the exact required duration
• Identifies short shots and other defects using machine vision

By pairing robotics with artificial intelligence, WPI achieves levels of defect detection and dimensional accuracy that far exceed traditional manual methods.

Automation at WPI isn’t limited to isolated machines, it’s built into our broader manufacturing strategy. Our in-house technologies, including CNC milling, pad printing, laser engraving, and hot stamping, can all be integrated into automated workflows.

This flexibility allows us to create complete, end-to-end automated solutions that improve:

• Cycle times
• Accuracy and repeatability
• Traceability and documentation
• Cost efficiency

Whether the project requires simple repetitive motion or a fully automated assembly process, WPI can design a system tailored to the customer’s needs.

At WPI, automation isn’t about replacing people, it’s about empowering them. By leveraging intelligent systems, we’re creating safer workplaces, enabling employees to focus on high-value tasks, and building more predictable, scalable production environments.

Automation is part of who we are: Innovative. Reliable. Built to perform.

Whether you’re exploring automation for improved efficiency, better quality, or competitive pricing, Wisconsin Plastics, Inc. is ready to help.

Contact us today to learn how our automation expertise can support your next manufacturing challenge.