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Process Automation & Retrofit for Mama’s Life Products

Client

Mama’s Life Products

Industry

Consumer Packaged Goods / Manufacturing

Background

Mama’s Life Products was attempting to implement automation in their mixing and pouring processes, which were previously entirely manual. Their goal was to improve efficiency, consistency, and throughput in production. 

Tilism Design Studio (TDS) was brought in to take over the project after a previous vendor’s attempt at automation had failed. The system was underperforming, required frequent manual intervention, and caused production bottlenecks and quality inconsistencies. TDS was tasked with stabilizing operations and delivering a costeffective automation solution without replacing all existing equipment. 

Challenge

  • Completely manual mixing and pouring processes causing inefficiency
  • A failed automation attempt by a previous vendor
  • Existing machinery and tooling could not be easily replaced due to cost constraints
  • Inconsistent output and quality issues
  • Limited documentation and poor system integration
  • Need to minimize downtime during the transition
The client required a solution that automated critical steps while preserving existing investments.

Our Approach

TDS conducted a detailed technical assessment of the existing manual and semi-automated processes, equipment, and control logic. Rather than a full system replacement, we implemented a retrofit-first strategy to control costs and reduce implementation time.

Key steps included:

  • Mapping the manual mixing and pouring processes and identifying bottlenecks
  • Reverse-engineering existing mechanical and electrical systems
  • Redesigning automation logic using a simplified and robust PLC architecture
  • Retrofitting existing machinery with new sensors, actuators, and safety interlocks
  • Improving material handling and sequencing to reduce manual steps
  • Integrating quality checks directly into the automated process

Solution Delivered

  • Retrofitted and upgraded the existing system instead of full replacement
  • Implemented a reliable PLC-based control system with clear fault diagnostics
  • Added sensors for real-time monitoring and improved process control
  • Optimized cycle times through improved sequencing and motion control
  • Reduced manual intervention while maintaining operator flexibility
  • Delivered a scalable design for future expansion

Results

  • Significant improvement in system reliability and uptime
  • Increased production throughput without additional floor space
  • Reduced labor dependency and operator fatigue
  • Lower capital expenditure by reusing existing equipment
  • Faster return on investment compared to a full new automation solution
Mama’s Life Products regained confidence in their production process and achieved a stable, repeatable operation aligned with their growth plans.

Why Tilism Design Studio

This project highlights TDS’s ability to:

  • Take over and fix failed automation projects
  • Retrofit and optimize existing equipment to save costs
  • Bridge the gap between manual processes and modern automation
  • Deliver practical, production-ready solutions—not just concepts
At TDS, we specialize in solving real-world manufacturing problems with smart engineering, hands-on execution, and a focus on long-term value.

Services Used: Process Automation · PLC Programming · Retrofit Engineering · Sensors & Controls · Mechanical & Electrical Integration

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