Industrial Automation Systems: Turnkey Robotic Automation for UK Manufacturers
We design, build and install industrial automation systems for UK factories: robot cells, automated production lines, palletising and end-of-line systems, machine tending and the PLC controls, conveyors, vision and safety that tie them together. Built around new or refurbished ABB, FANUC and KUKA robots, so you get proven automation at the right budget. Robotic automation cells from about £40,000.
Typical starting budget for a robotic automation cell
Refurbished robots can cut the robot cost by up to half
ABB, FANUC and KUKA robots in stock
Design, build, install, program, train and support
Industrial automation systems: what they are and what we build
An industrial automation system is a combination of machines, industrial robots, control systems (PLCs, HMIs and SCADA), sensors and safety equipment that carries out a manufacturing process with little or no manual work. The PLC and robot controllers follow a program, read sensors and vision systems, drive the robots, conveyors and tooling, and keep people safe, so the process runs the same way on every part, shift after shift. Learn more about the Challenges of Control Systems.
Most UK manufacturers don’t need a fully automated factory. They need one bottleneck automated well: a welding station, the end of a packing line, a CNC machine that sits idle at night. That is where we start. We look at the process, choose the right robot and equipment, then design, build and commission a complete industrial automation solution that your team can run and maintain.
Because Robot Store also sells new and refurbished robots, we can build the system around a robot that fits your budget, not just the newest model on a price list.
Types of industrial automation systems we design and install
Every system is built around your part, your cycle time and your floor space. These are the automation systems UK manufacturers ask us for most. Budgets are typical ranges for a complete, installed system, ex VAT. Discover more about ways to reduce costs in robotics and automation.
Robotic automation cells
A self-contained cell: robot, tooling, fixtures, guarding and controls on one footprint. The quickest way to automate a single process.
- Single or twin-station layouts
- Operator load / robot unload
- Fits next to existing machines
Typical budget £40k–£120k
Automated production lines
Several robots, conveyors and machines linked by one PLC so parts flow from station to station without manual handling.
- Multi-robot and multi-station lines
- Line PLC, HMI and SCADA
- Traceability and production data
Typical budget £200k–£500k+
Palletising and end-of-line automation
Case packing, palletising, stretch wrapping and labelling at the end of the line, often the fastest payback in a factory.
- Mixed SKUs and pallet patterns
- Pallet conveyors and safety scanners
- Layer pads, labels and wrapping
Typical budget £60k–£180k
Machine tending automation
A robot loads and unloads CNC machines, presses and moulding machines, so they keep running through breaks and unmanned shifts.
- CNC, lathe, press and injection moulding
- Part trays, drawers or conveyors
- Lights-out and night-shift running
Typical budget £50k–£150k
Welding automation systems
MIG/MAG, TIG and spot welding cells with positioners, torch cleaning and fume extraction for repeatable, high-quality welds.
- Single or twin-station weld cells
- Positioners and seam tracking
- Weld fixtures and fume extraction
Typical budget £60k–£200k
Material handling and pick-and-place
Robots that pick, place, sort, pack and transfer products between conveyors, machines and packaging, with vision where parts vary.
- Vacuum, mechanical and magnetic grippers
- Vision-guided picking
- Painting, coating and dispensing too
Typical budget £40k–£150k
Fixed, programmable, flexible or integrated: which type of automation do you need?
Industrial automation is usually grouped into four types. The right one depends on how many parts you make, how many variants you have and how often the product changes. Most of the systems we build are flexible automation, because a robot can be reprogrammed for the next product instead of being scrapped.
| Type of automation | What it is | Best for | Changeover | Examples |
|---|---|---|---|---|
| Fixed (hard) automation | Dedicated machines built for one product and one sequence | Very high volumes, one product, long product life | Slow and costly: the equipment is rebuilt | Transfer lines, bottling lines, stamping presses |
| Programmable automation | Equipment reprogrammed between batches of different products | Batch production at medium volumes | Hours: new program and tooling between batches | CNC machines, batch robot cells, PLC-controlled process plant |
| Flexible automation | Robots and controls that switch between part variants with little or no downtime | High mix, medium volume: most UK manufacturers | Minutes: select a program or the vision system adapts | Robotic welding, machine tending and palletising cells |
| Integrated automation | Machines, robots, MES and business systems linked so the whole site runs from one data flow | Large plants and fully automated factories | Managed centrally by software | Automotive body shops, lights-out factories, computer-integrated manufacturing (CIM) |
Not sure where your process fits? Our guide to robotics vs traditional automation compares robots with dedicated machines, and types of robots explains which robot suits which job.
Components of an industrial automation system
A working automation system is more than a robot. These are the building blocks we specify, supply and connect, and the parts that most affect reliability and cost.
The 5 levels of industrial automation (automation pyramid)
| Level | What it does | Typical equipment |
|---|---|---|
| 1. Field level | Senses and moves: the physical work | Sensors, actuators, motors, robots, grippers, conveyors |
| 2. Control level | Runs the sequence and logic in real time | PLCs, robot controllers, motion and safety controllers |
| 3. Supervisory level | Lets people monitor and run the process | HMI panels, SCADA |
| 4. Planning level (MES) | Schedules production and tracks quality | Manufacturing execution systems, traceability |
| 5. Enterprise level (ERP) | Links production to orders, stock and finance | ERP systems such as SAP or Sage |
Industrial robots
New and refurbished ABB, FANUC and KUKA robots chosen for payload, reach and speed. Browse robots for sale.
PLC and control systems
Siemens, Allen-Bradley and other PLCs that coordinate the robots, machines and conveyors. See robot control systems.
HMI and SCADA
Operator screens for recipes, alarms and production counts, and SCADA for supervising the whole line.
End-of-arm tooling
Grippers, vacuum heads, welding torches, spray guns and tool changers designed for your parts.
Conveyors and material handling
Belt, roller and pallet conveyors, part feeders, buffers and transfer systems that keep parts moving.
Sensors and machine vision
Cameras, laser scanners and sensors for part location, inspection, measurement and seam tracking.
Fixtures and positioners
Jigs, rotary tables, tracks and positioners that present each part in the same place every cycle.
Safety systems
Fencing, interlocked doors, light curtains, area scanners and safety PLCs, designed to the risk assessment.
Networks and data
PROFINET, EtherNet/IP and OPC UA connections to your MES, ERP and production dashboards.
How much does an industrial automation system cost?
A simple robotic automation cell typically costs £40,000 to £80,000, a standard robot system with tooling, controls and safety £80,000 to £200,000, a complete automated production line £200,000 to £500,000, and a complex multi-robot system more than £500,000 (ex VAT, installed). The robot itself is usually only a quarter to a third of the total. The rest is tooling, controls, safety, engineering, installation and training.
| Automation system | Typical application | What is included | Indicative investment |
|---|---|---|---|
| Simple robotic automation | One robot, one process: a basic cell for machine tending, pick-and-place or palletising | Robot, gripper, guarding, basic controls, installation | £40k–£80k+ |
| Standard automation system | A robot-based system with custom tooling, PLC, HMI, vision or a positioner | Robot, tooling, PLC and HMI, safety, programming, commissioning | £80k–£200k+ |
| Complete manufacturing automation | An automated production line or end-of-line system with several stations | Several robots or machines, conveyors, line PLC, SCADA, integration | £200k–£500k+ |
| Complex multi-robot system | Advanced lines with many robots, machines, vision and MES links | Full engineering, simulation, multi-robot coordination, data systems | £500k+ |
Where the money goes in a typical system
| Cost element | Typical share of budget |
|---|---|
| Robot and controller | 25–35% |
| Tooling, fixtures and positioners | 10–20% |
| Conveyors and handling equipment | 5–15% |
| PLC, HMI, vision and electrics | 10–15% |
| Guarding and safety systems | 5–10% |
| Engineering, programming, installation and training | 20–30% |
Shares are typical ranges for a single robot cell and change from project to project.
What affects the cost of an automation system?
- Number of robots and stations
- New or refurbished robots
- Part size, weight and number of variants
- Cycle time and production volume
- Custom tooling and fixtures
- Conveyors and material handling
- PLC, HMI, SCADA and data links
- Vision and sensor systems
- Guarding, safety and CE / UKCA work
- Installation, commissioning and training
Cut the cost with refurbished robots. Building the system around a fully tested, warrantied used robot, with new tooling, controls and safety, can lower the initial investment considerably. See why choose refurbished robots.
Looking for the price of a robot or a single robot cell rather than a whole system? See robot prices. For the cost of the integration service, see robotic integration.
Where manufacturers save money with automation
The return on an automation system comes from more output, fewer rejects and fewer hours spent on repetitive, heavy or dangerous jobs. How much you save depends on your process, volumes, shift pattern and the investment. Many single-robot cells pay back in one to three years on two-shift work.
The labour your team saves can move to set-up, quality and maintenance roles, which helps when skilled operators are hard to recruit.
Higher production output
Robots keep the same pace through breaks, nights and weekends, and are not slowed down by heavy or awkward parts.
Consistent quality
The same program on every part means fewer reworks, fewer customer complaints and easier certification.
Safer work
Automate lifting, welding fumes, painting and press loading, cutting injuries and RSI.
Lower labour cost per part
Fewer manual hours on repetitive tasks, and operators move to higher-value work.
Less waste and scrap
Accurate, repeatable processes use less material, paint, wire and energy.
Less downtime
Fault messages, data and planned maintenance keep a well-designed system running.
Want to check the numbers? Our robot prices and ROI guide shows how to work out payback. For how automation is changing UK factories, read industrial manufacturing trends.
New vs refurbished automation systems
An automation system can be built with new robots, refurbished robots or a mix. Because we sell both, we can recommend whichever gives the best result for your budget and production plan. The tooling, controls and safety are always new and designed for your system.
| Refurbished robots in a new system | New robots in a new system | |
|---|---|---|
| Robot cost | Much lower: often around half the new price | Full list price |
| Lead time | Robots usually in stock in the UK | Depends on manufacturer lead times |
| Warranty | Robot Store warranty on the refurbished robot | Manufacturer warranty |
| Technology | Proven controllers such as ABB IRC5, FANUC R-30iA/iB and KUKA KRC4 | Latest controllers and software options |
| Best for | Tight budgets, first automation projects, proving ROI, standard tasks | Long-term projects, newest features, cobots and high-speed lines |
| Spares and support | Parts and repairs from our stock | Manufacturer and Robot Store support |
The right answer is often a mix: refurbished robots for standard tasks with new tooling, PLCs and safety, so you get a reliable system for less. See industrial robots for sale or the ABB, FANUC and KUKA robots we stock.
Industrial automation solutions by application and industry
We build automation systems for most manufacturing processes. Each application below links to a full guide with the robots, layouts and costs.
| Application | Typical automation system | Industries | Guide |
|---|---|---|---|
| Welding | Robotic MIG/MAG, TIG or spot welding cell with positioner | Metal fabrication, automotive, agricultural and construction equipment | Welding robots |
| Palletising and end of line | Palletising cell with pallet conveyors, wrapping and labelling | Food and drink, packaging, building materials, timber | Palletising robots |
| Machine tending | Robot loading CNC machines, presses or injection moulding machines | Precision engineering, plastics, automotive parts | Milling robots |
| Assembly | Robotic assembly stations and assembly lines | Automotive, electronics, consumer goods | Robotic assembly |
| Painting and coating | Robotic paint booth, coating or dispensing system | Automotive, aerospace, furniture, plastics | Robotic painting |
| Milling and finishing | Robotic milling, trimming, deburring and polishing cells | Foam, wood, composites, stone, aluminium | Robotic milling |
| Material handling and packing | Pick-and-place, sorting, case packing with vision | Food, pharmaceuticals, logistics, e-commerce | Manufacturing robots |
Automotive
Welding, assembly, painting and parts handling for vehicles and Tier 1 and 2 suppliers.
Metal fabrication
Welding, cutting, bending, machine tending and handling of heavy parts.
Food and beverage
Hygienic handling, case packing and palletising at the end of the line.
Packaging and logistics
Packing, sorting, palletising and depalletising of cases, bags and trays.
Plastics and moulding
Injection moulding take-out, trimming, assembly and packing.
Electronics and general manufacturing
Small-part assembly, testing, inspection and flexible automation for high-mix work.
How to choose the right industrial automation system
Answer these eight questions before you ask for quotes. They decide the type of robot, the layout and most of the cost, and they let suppliers quote like-for-like.
Production volume
How many parts per shift, and how many shifts? Volume decides whether fixed, programmable or flexible automation pays.
Cycle time
The time allowed per part sets the robot speed, the number of robots and whether you need twin stations.
Part size, weight and variants
Payload and reach come from the heaviest part plus the gripper. More variants need flexible tooling or vision.
Robot reach and payload
Choose a robot with headroom: around 20–30% spare payload and reach for the gripper and future parts.
Floor space and layout
Measure the space, access for forklifts and operators, and how parts arrive and leave the system.
Safety requirements
Guarding, scanners, interlocks and a risk assessment are needed for every system, and they affect the footprint.
Integration with existing equipment
Which machines, conveyors, PLCs and IT systems must the new system talk to?
Budget and expected ROI
Set a budget and payback target early, and decide whether refurbished robots are an option.
Automating an existing production line
Good factory automation doesn’t need a new factory. Most of our projects add a robot cell or an automated station to a line that is already running, or upgrade old automation that is hard to support. We plan the work around your production so the changeover happens over a weekend or a planned shutdown.
- Automate one bottleneck first: the station that limits output or is hardest to staff
- Retrofit and upgrade: replace obsolete PLCs, HMIs or robots and keep the mechanical equipment
- Connect to Industry 4.0: OPC UA and MQTT links to MES, OEE dashboards and remote support
- Add vision and sensors so older machines can handle more part variants
- Re-use robots you already have: we reprogram and redeploy existing robots for new jobs
Changing an existing robot program? Our robot programming engineers can help. Training your team to run the new system? See robot training.
Our automation project process: from assessment to production
One team takes your system from the first visit to full production, so there is one point of responsibility for the robot, the controls and the safety. A single robot cell typically takes 8 to 16 weeks from order to production; larger lines take longer.
Need a specialist to integrate a robot into equipment you already have? Our robotic integration service covers that in detail.
Application assessment
We visit or review videos, drawings and sample parts, and agree what the system must achieve: output, cycle time and budget.
Concept and simulation
Layout, robot choice and a 3D simulation to prove reach and cycle time, with a fixed-price proposal.
Detailed design
Mechanical, electrical and control design: tooling, fixtures, guarding, PLC and HMI, plus the risk assessment.
Build and factory test
The system is built and programmed, then tested with your parts before it leaves us (FAT).
Installation and commissioning
Installed at your site, connected to your line, commissioned and run up to full speed (SAT).
Operator and maintenance training, documentation, backups, spares and remote or on-site support.
Why choose Robot Store for industrial automation solutions?
Robots in stock
Hundreds of new and refurbished ABB, FANUC and KUKA robots, so projects are not held up by robot lead times.
Design and build in-house
Our engineers design the tooling, controls and safety and build the system, then test it before delivery.
One point of responsibility
Robot, PLC, safety and programming from one supplier, so there is no finger-pointing between contractors.
Programming and training
We write the robot and PLC programs and train your operators and maintenance team on the finished system.
Spares and support
Robot parts, repairs and remote support from our UK stock to keep the system running for years.
UK-wide and international
Based in the UK, supporting manufacturers across the UK and exporting complete systems worldwide.
Get an industrial automation system quote
Tell us what you want to automate. An automation engineer will review it and come back within one working day with the next steps: usually a short call, then a concept, a layout and an indicative price. Photos, videos, drawings or sample parts help us quote faster and more accurately.
- An indicative budgetFor the system and the options, ex VAT
- A recommended layoutRobot, tooling, handling and safety
- New or refurbished optionsSo you can compare cost and payback
- A realistic timescaleFrom order to full production
Prefer email? Write to info@robot-store.co.uk
Industrial automation systems: frequently asked questions
What is an industrial automation system?
An industrial automation system is a set of machines, industrial robots, control systems (PLCs, HMIs, SCADA), sensors and safety equipment that carries out a manufacturing process with little or no manual work. The controls follow a program and react to sensors, so the process runs the same way every time.
What are the main types of industrial automation?
There are four: fixed (hard) automation for very high volumes of one product, programmable automation for batch production, flexible automation for high-mix work with quick changeovers, and integrated automation, where machines and business systems run as one. Most robot systems are flexible automation. See types of automation compared.
What are examples of industrial automation systems?
Robotic welding cells, palletising and end-of-line systems, robots tending CNC machines, automated assembly lines, robotic paint booths, pick-and-place and packing systems with vision, and conveyor lines controlled by PLCs and SCADA.
How much does an industrial automation system cost?
A simple robotic automation cell typically costs £40,000 to £80,000, a standard robot system £80,000 to £200,000, a complete production line £200,000 to £500,000 and complex multi-robot systems more than £500,000, ex VAT. See the automation cost table.
What does an industrial automation system include?
Depending on the application: industrial robots, end-of-arm tooling, fixtures and positioners, conveyors, a PLC and HMI, sensors and machine vision, guarding and safety devices, and the programming, installation, commissioning and training to make it work.
What is the difference between a PLC and a robot controller?
The robot controller moves the robot along its programmed paths. The PLC runs the wider system: it tells the robot when to start, controls conveyors and machines, reads safety devices and talks to the HMI. They exchange signals over a fieldbus such as PROFINET or EtherNet/IP. See robot control systems.
How long does an automation project take?
A single robot cell typically takes 8 to 16 weeks from order to production, including design, build, factory testing, installation and commissioning. Larger lines and multi-robot systems can take six months or more. Using robots from stock shortens the lead time.
What is the payback period for industrial automation?
Many single-robot cells pay back in one to three years, especially on two- or three-shift work. Payback depends on the labour saved, extra output, less scrap and the system cost. Our robot prices and ROI guide shows how to work it out.
Can you automate an existing production line?
Yes. Most of our projects add a robot cell or automated station to a line that is already running, or upgrade old PLCs, HMIs and robots. We plan the installation around planned shutdowns to keep downtime short.
Can refurbished robots be used in an automation system?
Yes. A fully tested, warrantied refurbished robot can reduce the robot cost considerably, and we combine it with new tooling, controls and safety. It suits standard tasks and first automation projects. See why choose refurbished robots.
Is industrial automation worth it for a small manufacturer?
Often, yes. A single robot cell on one bottleneck, such as welding, machine tending or palletising, is affordable for many small and medium manufacturers, especially with refurbished robots. Start with the job that is hardest to staff or limits output.
Do automation systems need CE or UKCA marking?
Yes. A complete automation system placed on the market or put into service in Great Britain must meet the machinery safety rules, with a risk assessment, technical file, declaration and UKCA (or CE) marking. Your system must also meet PUWER at your site. We include safety design and documentation.
Which robot brands do you use in automation systems?
Mainly ABB, FANUC and KUKA, new or refurbished, because they are reliable and well supported in the UK. See ABB robots, FANUC robots and KUKA robots.
Can Robot Store design and build a complete automation system?
Yes. We handle the full project: assessment, concept and simulation, mechanical, electrical and control design, build and testing, installation, commissioning, programming, training and after-sales support.
Do you provide training and support after installation?
Yes. Every system includes operator and maintenance training, documentation and program backups. After that we offer remote support, on-site visits, spares and robot training courses.
What information do you need for a quote?
What you want to automate, the parts (sizes, weights and number of variants), the output per shift and cycle time, the available floor space, any existing equipment to connect to, your budget and timescale. Photos, videos or drawings help. Use the quote form.
Ready to automate your production?
Tell us the process you want to automate. We’ll suggest the right system, the robots to use and a realistic budget, new or refurbished.
