Company Overview
Itech (Injection Technology Corporation), located in Arden, North Carolina, is a specialized custom molder producing precision thermoplastic components—such as electric meter covers, dental appliance cases, and spools. With 95 employees operating 23 injection molding machines in a 30,000-square-foot facility, maintaining efficiency is paramount.
The Challenge
Itech sought to modernize its production process amid growing demands and tight margins. At a robotics seminar and factory visit, Itech leadership—led by President Carl Morris—saw ABB’s six-axis robot in action and recognized its potential. Despite the higher initial price compared to conventional gantry robots, Morris opted for ABB’s solution, envisioning a strategic long-term advantage.
Implementation
Working with system integrator ACS Group, Itech installed an ABB IRB 4400 robot—nicknamed “Abby”—which took approximately 14 weeks to set up. The robot’s role was to automate spool assembly: removing two halves from a Toshiba injection molding machine, aligning and fitting them, then inserting the assembled spool into an ultrasonic welder.
Results & Benefits
Striking ROI: Abby paid for itself in under eight months—well ahead of typical automation recoup timelines.
Labor Efficiency: Manual hours were slashed by 45%, significantly reducing repetitive strain and freeing workers for higher-value activities.
Cycle Time Reduction: Assembly cycle times dropped by 23%, enabling faster throughput.
Increased Capacity: As molding times shortened, Itech gained flexibility to run additional products on its existing machinery.
Safety & Reliability: With reduced operator fatigue and consistent performance, Itech maintained its award-winning safety record.
Business Growth: The automation helped Itech achieve growth rates of approximately 9% in 2004, 12% in 2005, and an anticipated 25% in 2006.
Scalable Strategy: Encouraged by success, Itech placed an order for a second ABB robot—and plans to eventually have Abby serve multiple machines.
“It was 7.8 months [to get ROI],” says Morris, reflecting on how surprisingly fast the investment paid off—especially when most capital expenses typically take two years or more to recover.
Summary
By investing in the ABB six-axis robot, Itech transformed its manufacturing efficiency and productivity. Faster cycles, reduced labor, improved safety, and strong ROI made the robot a powerful competitive asset—and set the stage for further automation and growth.
