Please note: To respect confidentiality agreements, some technical specifications and visuals cannot be disclosed.

Customer Challenge

Our client required an automated solution to neatly coil bicycle chains, place them into plastic packaging, and apply a reliable seal - at high speed and with consistent quality. The manual and semi-automated processes in use were labor-intensive and limited scalability, while product presentation and repeatability were becoming increasingly important.

The challenge was to develop a fully automated production machine that could handle different chain types within one production line, while supporting lean manufacturing principles such as one-piece flow. Accuracy, reliability, and ease of operation were essential, as well as a smooth transition from prototype to full-scale mass production

Result

The automated chain coiling and packaging solution was successfully developed and implemented, delivering:

• Design and development of the machine, including packaging. 
• Fully automated coiling, packaging, and sealing of bicycle chains.
• High accuracy and repeatability through digitally controlled motion systems.
• Support for one-piece-flow manufacturing, improving efficiency and throughput.
• Flexibility to handle multiple chain variants within a single production line.
• Improved product presentation and consistent packaging quality.

The solution enabled our client to scale production while maintaining precision, quality, and operational efficiency.

Applied Technology

• Numerically Controlled Machinery: Ensures precise coiling, positioning, and handling of chains.
• Automated Packaging & Sealing System: Reliable insertion into plastic packaging followed by consistent sealing.
• Flexible Motion Control: Configurable for different chain lengths and product variants.
• One-Piece-Flow Production Design: Optimized for lean manufacturing and minimal work-in-progress.
• Integrated Quality & Process Control: Designed for repeatability and long-term stability in mass production.

TSG Contribution

TSG partnered with the client to develop and industrialize the complete production solution. Starting from a proven principle and pilot setup, our team translated the concept into a fully scalable mass production machine.

TSG was responsible for the packaging design, mechanical design, control architecture, and system integration. The machine is assembled, tested, and validated at our workshop in Eindhoven, including operator training and the Factory Acceptance Test (FAT). After approval, the system was commissioned on-site at the clients factory, ensuring a smooth start-up and reliable operation.

The result is a state-of-the-art manufacturing solution that combines precision engineering, flexibility, and lean production—ready for high-volume bicycle chain packaging with consistent quality.