Case Studies
Engineering Projects & Case Studies.
This page provides a quick summary of representative THH Engineering projects at the top, with detailed case study content below.
Use the buttons for each project to jump directly to the detailed write-up.
Robotic Methadone Dose Assembly System (ZING)
First robotic methadone dose assembly system for opioid treatment programs, replacing a manual process with a precise, automated, hands-free workflow.
LidStick Bagging System
Fully automated system to unload LidSticks from an injection molding machine and individually package them in a continuous web of bags.
Chromatography Columns Packing System
Automated fluidic processing tool designed to transfer proprietary media under pressure into chromatography columns with repeatable high-pressure performance.
Press-Loading Pick-and-Place System
Pneumatic pick-and-place automation system for semi-automated die stations that improved production yield by reducing operator variance.
Project Details
Each project below expands on the summary above with additional technical, engineering, and implementation detail.
Robotic Methadone Dose Assembly System (ZING) – Automation & Product Development
Overview
THH Engineering led the development of ZING, the first robotic methadone dose assembly system designed for opioid treatment programs (OTP). The system replaces a traditionally manual process performed by nursing staff or pharmacists with a fully automated, precise, and hands-free solution.
ZING enables clinics to improve efficiency, accuracy, and patient care by allowing staff to focus more time on clients rather than manual dose preparation.
The Challenge
Methadone dose preparation is typically a manual, time-consuming process requiring precision and strict compliance. This creates challenges including:
Labor-intensive workflows
Risk of human error
Limited scalability for growing patient demand
The Solution
THH Engineering designed and developed a fully integrated automation system capable of handling the complete dose assembly process..
Key system capabilities:
Precision methadone pumping
Automated bottle capping
Labeling and barcode scanning
Heat foil sealing
End-to-end system integration
The system was engineered for accuracy, reliability, and repeatability in a regulated medical environment.
Results
Successful development of a first-of-its-kind robotic system
Significant reduction in manual labor requirements
Improved dosing accuracy and process consistency
Scalable platform for future system expansion
ZING now serves as the foundation for advanced systems including:
Proof – remote dose verification
Booth – remote nurse support and dispensing
Additional Information
For more information, visit:
See ZING in action
Click the video below (sound recommended for best experience).
LidStick Bagging System
Medical component handling and packaging automation
Overview
A medical client provides consumables to ophthalmologists, including the LidStick®, used for eyelid manipulation during diagnostic procedures.
The client engaged THH Engineering to develop a solution for unloading LidSticks from an injection molding machine and packaging them individually in a continuous web of bags.
The Challenge
The process required:
Reliable unloading directly from injection molding
Individual handling of small, delicate components
Integration with a continuous bagging system
Consistent, high-throughput operation
Manual handling or semi-automated approaches would limit scalability and prodess stability.
The Solution
THH Engineering developed a fully automated system integrating molding output with downstream packaging.
Key system elements:
Automated unloading from injection molding machine
Part handling and transfer system
Continuous web bagging integration
Production-oriented mechanical system design
Engineering Scope
THH Engineering provided:
Engineering analysis and concept development
Mechanical system design
Project management
Manufacturing coordination
Assembly and installation
Integration with injection molding equipment
Results
Fully automated bagging system implemented
Improved consistency and throughput
Reduced manual handling requirements
Seamless integration with existing production process
Services
Application Engineering • Engineering • Project Management
Chromatography Columns Packing System
The project involved developing an automated fluidic processing tool designed to transfer a proprietary media under pressure into chromatography columns intended for use with automated chromatography instruments. The design featured a fluidics system with an interchangeable manifold, allowing simultaneous packing of one to three columns. Due to the highly aggressive acids in the packing media, the system incorporated 316SS fittings and seamless SS tubing rated up to 9,000 psi to ensure durability and safety under high-pressure conditions. THH was responsible for engineering and managing the engineering team.
After the initial development, the end user purchased numerous repeat systems.
Services: Application Engineering –Engineering – Project Management
Press-Loading Pick-and-Place System
Our customer assembles stamped components in a semi-automated die station. Manually loading of small parts into the die resulted in production yield fluctuations due to operator variance. The customer contracted with THH to perform a cycle time study, generate a concept for automation, and establish project cost and timeline for a pneumatic Pick-and-Place system. THH’s design used a vibratory feeding system to present parts to the pick-and-place system, which then orients parts and precisely locates them prior to install into the die. After the customer decided to implement the automation, THH managed the project and oversaw engineering, manufacturing, assembly, installation with the existing machine, and performed the production run-off. The installed system increased production yields up to 25%.
Services: Application Engineering – Engineering – Project Management