Custom Automation Solutions

Hemang Joshi, Founder hjLabs.in By Hemang Joshi · Founder, hjLabs.in · MSc Electronics · Updated May 3, 2026

We design and build machines to your exact specifications. Tell us what you need — we'll engineer it from scratch in our Gandhinagar facility.

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Engagement Process

A predictable 5-step path from your first enquiry to a fully commissioned machine on your shop floor.

1
Discovery

Free 30-minute consultation. We capture process goals, cycle time, part geometry, environment constraints, and budget envelope.

2
Feasibility & Spec

Engineering report with concept CAD, BOM, fixed timeline, and a binding price range. NDA signed; PoC milestones agreed.

3
Prototype

Working proof-of-concept on your real parts. You validate cycle time, repeatability, and ergonomics before committing to production build.

4
Production Build

Manufacture and assemble in our Gandhinagar facility. Full FAT (Factory Acceptance Test) with video documentation before despatch.

5
Commissioning + Training

On-site installation, SAT (Site Acceptance Test), operator training, and 12-month warranty plus optional AMC.

Case Studies — Real Outcomes

Anonymized snapshots of recent custom automation deployments. Names withheld under NDA; metrics measured on the client floor.

Auto Components — Gujarat
Vision QC Station Retrofit

Problem: Manual visual inspection was missing 12% of cosmetic defects on a brake-component line.

Solution: Bolted-on vision QC station with industrial camera, GPU-based defect classifier, and PLC reject pusher integrated with the existing conveyor.

Outcome: 92% defect catch rate, customer reject rate dropped 4.7× in 90 days. ROI in 11 months.

Cable Assembly — Maharashtra
Wire Cut + Tag Line

Problem: Hand-cut, hand-tagged wire harness operation was the throughput bottleneck on a 3-shift cable assembly factory.

Solution: Three-station automated cell — programmable cut-strip-mark — based on a customised AutoCut V2, integrated with a thermal tag printer and bin sorter.

Outcome: 4× throughput, headcount on the line halved, ₹18L/yr labour savings. Full payback in 14 months.

Pharma Packaging — Gujarat
Track-and-Trace Integration

Problem: Existing carton line lacked unit-level serialisation required for export markets and DSCSA-style compliance.

Solution: Inline laser marking + camera-based 2D-code verification + aggregation station, with serial numbers reported to the client's L4 ERP via REST API.

Outcome: 100% serialisation compliance, zero rejected export shipments in the 12 months post go-live.

Project Sizes & Pricing

Transparent indicative ranges. Final quote depends on cycle time, integration complexity, and certifications.

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Single-Machine Retrofit
₹50,000 – ₹2,00,000

4–6 week delivery

Add IoT, sensors, or a bolt-on automation module to an existing machine. Examples: vision QC head, IoT OEE box, pneumatic feeder. Typical ROI: 6–12 months. Browse our automation components as a starting point.

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Cell Automation
₹3,00,000 – ₹15,00,000

8–14 week delivery

Single-process automation cell — feeder + actuator + QC + reject. Often built around a customised version of our AutoCut V2 or similar standard product. Typical ROI: 12–18 months.

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Full-Line System
₹15L – ₹1 Cr+

16–24 week delivery

Greenfield production line — multi-station, conveyor-linked, with central HMI/SCADA and ERP integration. Suitable for manufacturing-grade rollouts and multi-shift operation. Typical ROI: 18–30 months.

Prices indicative for FY2026. Cross-reference with our standard AutoCut V2 product page for retrofit-ready building blocks.

Solution Types

We build across the full range of industrial automation requirements.

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Wire Harness Automation

Automatic wire cutting, stripping, crimping, and harness assembly machines. Custom length settings, multi-wire capability, HMI control. Like our AutoCut V2 wire cutter, which is available in both standard and custom configurations.

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PCB Assembly Automation

Automated soldering systems, selective wave soldering, pick-and-place assistance, and inline inspection fixtures for PCB production. Our AutoSolder 6 soldering robot is a proven starting point for custom configurations.

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Component Assembly

Semi-automatic or fully automatic assembly jigs and fixtures for small components. Reduces operator error and doubles throughput. See our semi-automatic spring coiling machine as an example of the semi-automatic format.

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Packaging Automation

Automatic counting, bagging, labeling, and carton sealing machines. Configurable for different product sizes and packaging formats.

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Testing & QC Machines

Custom electrical test benches, leak test systems, functional testers and vision inspection systems integrated with production lines.

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Conveyor Systems

Motorized belt and roller conveyors with variable speed, workstation stops, sensors, and integration with upstream/downstream equipment.

Why hjLabs

What sets us apart from other automation vendors.

history
7+ Years Experience

Hundreds of machines designed and deployed across India and globally since 2017.

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In-house Manufacturing

We control the full build — no outsourcing. Faster turnaround, better quality, single point of accountability.

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ISO Quality Process

Documented design review, in-process QC checks, and final acceptance testing before every machine ships.

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After-sales Support

12-month warranty, remote troubleshooting, spare parts availability and on-site service visits when needed.

Industries We Serve

We have delivered automation solutions across these sectors.

memory Electronics Manufacturing cable Automotive Wire Harness wb_sunny Solar Energy emoji_objects LED Lighting bolt Electrical Panel Assembly kitchen Consumer Appliances directions_car Automotive medication Pharmaceutical

Our Standard Automation Products

Need a proven off-the-shelf solution? Browse our range of ready-to-order machines — or request a custom variant.

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Automatic Wire Cutting & Stripping Machine
Programmable lengths, multi-wire
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Automatic Soldering Machine
PCB & through-hole soldering
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Automatic Spring Coiling Machine
Compression & torsion springs
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Automatic Winding Machine
Coil, bobbin & transformer winding
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IoT Production Monitoring System
Real-time OEE & downtime tracking
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Automatic Cable Coiling Machine
Fixed & figure-8 coil winding
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Automatic Wire Twisting Machine
Pair & multi-conductor twisting

Don't see what you need? Contact us — we build fully custom machines to your exact requirements.

Local to Gujarat? See our industrial automation services in Ahmedabad & Gandhinagar. Adding AI to your line? Explore computer-vision inspection and predictive maintenance.

Outside Gujarat? We deliver custom automation cells, retrofits, and AI/ML add-ons to plants nationwide through our city-specific service hubs: industrial automation services in Mumbai (BFSI, pharma corridor, MMR auto-component), Bangalore (electronics, aerospace, EV at Peenya/Hosur/Bidadi), Pune (Tier-1 auto supply at Chakan/Ranjangaon, Hinjewadi CDMO pharma), and Delhi NCR (Manesar/Gurgaon auto, Noida electronics, Faridabad SME).

Frequently Asked Questions

Common questions about our custom automation service.

hjLabs.in builds a wide range of custom industrial automation machines including wire cutting and stripping machines, soldering automation systems, winding machines, PCB assembly automation, IoT-integrated production line machines, packaging automation, testing and QC machines, and conveyor systems. If you have a production process that can be automated, we can engineer a solution for it.
Build time depends on complexity. Simple semi-automatic machines typically take 4–6 weeks from design approval to delivery. Mid-complexity fully automatic machines take 8–12 weeks. Complex multi-station production lines can take 12–20 weeks. We provide a detailed project timeline after reviewing your requirements.
There is no minimum order quantity — we build single custom machines as well as batches of multiple identical units. Whether you need one prototype or ten production-ready machines, we can accommodate your requirement. Contact us with your specifications for an indicative quote.
Yes. Every custom machine comes with complete operator manuals, wiring diagrams, and video documentation. We provide remote installation support via video call for all machines, and on-site installation and training visits are available for larger projects. All machines include a 12-month after-sales warranty.
Absolutely. We specialize in retrofitting automation into existing production lines without requiring a complete rebuild. Our engineers will assess your current setup and design automation modules that integrate seamlessly with your existing equipment, minimizing downtime and capital expenditure.
Typical payback periods for hjLabs.in custom automation projects range from 8 to 18 months. Single-machine retrofits (₹50,000–₹2,00,000) often pay back in 6–12 months from labour and rework savings. Cell-level automation (₹3L–₹15L) typically returns capital in 12–18 months through 2–4× throughput gains and consistent quality. Full-line systems pay back over 18–30 months but unlock multi-shift operation and significant scrap reduction. We share an indicative ROI model in our feasibility assessment.
You own the machine outright on full payment, including the right to operate, modify, and resell it. For project-specific IP — custom mechanical designs, control logic, and HMI software written for your application — you receive a perpetual, royalty-free license. hjLabs.in retains rights to its underlying platform code, generic mechanical modules, and reusable control libraries. Full mechanical CAD, electrical schematics, BOMs, and PLC code are delivered as part of the handover package. NDA is signed before any technical discussion.
Every machine ships with a 12-month parts-and-labour warranty. After that, you can opt in to an Annual Maintenance Contract priced at 5–8% of the machine cost per year. AMC covers two preventive-maintenance visits, priority remote support via WhatsApp/video, free firmware updates, and a 25–40% discount on spare parts. Critical spares like sensors, drives, and controllers are stocked locally for 48-hour replacement turnaround anywhere in India.
hjLabs.in is headquartered in Gandhinagar, Gujarat and serves clients pan-India with installation and support visits — major hubs include Ahmedabad, Vadodara, Surat, Mumbai, Pune, Bengaluru, Chennai, Hyderabad, Delhi-NCR, and Coimbatore. We also export custom automation machines worldwide, with prior deployments in the UK, UAE, USA, Germany, Singapore, and Australia. International installations are commissioned via remote video supervision plus, where feasible, an on-site engineer visit.
Standard automation machines (like our AutoCut V2 or AutoSolder 6) are designed for the most common industrial use cases, ship in 1–2 weeks, and are priced from ₹25,000 to ₹3 lakh. Custom automation is engineered to your exact process — your fixture, your cycle time, your part geometry, your integration with upstream and downstream equipment. Custom builds start at ₹50,000 for simple retrofits and scale into crore-plus territory for full production lines. Choose standard when an off-the-shelf machine meets 80%+ of your needs; choose custom when process specifics or throughput requirements demand a purpose-built solution.

Share Your Requirements

Have an automation challenge? Describe your process and we'll provide a free feasibility assessment and indicative quote within 24 hours.

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