Innovation in Action: Our Research & Development Team
At Kaufman Engineered Systems, innovation isn't just a buzzword — it’s a process. Our dedicated Research & Development (R&D) team plays a pivotal role in driving automation technology forward, ensuring every system we build reflects the latest advancements in performance, efficiency, and reliability. The R&D team works behind the scenes to prototype, test, and refine solutions that improve uptime, throughput, customer ROI, and operator ergonomics and safety.
Our Role - Prevent Problems Before They Exist: R&D is more than troubleshooting—it's forecasting the future of automation. Like a weather station anticipates storms, our team detects inefficiencies and limitations early through advanced simulation software and feasibility studies. This foresight prevents costly setbacks and maximizes operational success for our customers.
A Dual-Discipline Team: Electrical & Mechanical Engineering in Harmony
Our R&D team is uniquely structured to bring together both electrical and mechanical engineering expertise to continually push boundaries and raise the bar on the solutions Kaufman can provide for our customers.
Click the image to learn more about how the R&D team utilizes simulation software.
- Electrical Engineering – Controls, Integration, and Innovation
Our R&D electrical engineer leads all things involving power, wiring, controls, sensors, and programming. Whether he's configuring advanced conveyors on our K-Force demo system or programming simulations to help our sales team visualize solutions, the electrical R&D engineer ensures our systems are smarter, safer, and more connected. They also stay ahead of the curve by evaluating emerging technologies — from distance sensors for robotic corner board applications to 3D safety mapping systems — that may give Kaufman or our customers a competitive edge.
- Mechanical Engineering – Design, Testing, and Prototyping
On the mechanical side, our engineer handles physical components — from designing brackets for sensors to building and testing new stretch head mechanisms. Using 3D modeling tools like Autodesk Inventor and detailed 2D shop drawings, they create everything from full test fixtures to laser-ready part files. Their work brings ideas from digital design to real-world function, with iterative testing to ensure performance in real-time environments.
Together, this dual-discipline team enables rapid prototyping, design refinement, and continuous improvement — all tailored to the practical needs of our customers.
Real-World Examples of R&D at Work
Chocolate Totes – Vacuum vs. Clamp: When a customer that manufactures and distributes chocolates presented new chocolate tote designs, Kaufman’s R&D team stepped in before a final concept or quote was in place. Through simulation, the team validated that vacuum-based gripping could compensate for the lack of structural clamp points. Though bowing issues arose during trials, our proactive testing helped inform product direction early — saving time and expense prior to this project being finalized and implemented.
Robotic Labeling – Upside-Down Engineering: Faced with label adhesion issues due to suction interference, our team flipped the script — literally. By designing an upside-down pick mechanism for a FANUC LR Mate robot, they ensured smooth label pickup without bunching. This unique orientation minimized wear on robotic joints and improved cycle time, setting a new standard for labeling efficiency.
Corner Boarding Reinvented – Smart Triangulation: Our proprietary corner boarding system uses sensor-guided triangulation to ensure pinpoint accuracy when placing corner boards on variable pallet loads. This solution drastically improves placement speed while eliminating manual correction. Built into our stretch wrapper platforms, it reduces cycle times and increases throughput — all without exposing our proprietary geometry methods.
Gen 4 Stretch Head – A Fully Integrated Solution for Smarter, Safer Stretch Wrapping: Every few years, Kaufman's R&D team releases new generations of components, such as the fourth generation of our stretch head, which is currently under development. This release will represent a major leap forward in performance, combining mechanical refinement and control innovation. It features improved gear accessibility and more efficient film pre-stretching for easier maintenance and longer-lasting performance. Integrated cut-grip technology allows for precise dual-stack pallet wrapping, reducing system complexity and increasing flexibility. Paired with our in-development automated film change system, the Gen 4 stretch head minimizes manual intervention, enhances uptime, and supports safer operation — all within a more streamlined design built for today's high-demand environment. Each generation is built on the lessons of the last, driven by real-time customer feedback and hands-on R&D testing.
PROOF OF CONCEPT BEFORE PRODUCTION:
Our team doesn't wait until the system hits the floor to start solving problems. Whether it’s vacuum gripping, label application, or servo-controlled sorting, Kaufman’s R&D team simulates, tests, and validates before designs are finalized. This proactive approach reduces risk, accelerates implementation, and ensures the final system delivers as promised.
Staying Ahead of the Curve with Kaufman
When customers come to us with a challenge, our R&D team rolls up their sleeves — designing, testing, and refining creative solutions that deliver measurable results. Innovation at Kaufman doesn’t stop in the lab. Our R&D team actively explores next-generation technology at major automation expos and collaborates with vendors to evaluate new sensor systems, safety innovations, and automation tools that could be integrated into our systems in the future. This proactive approach helps ensure Kaufman solutions are always positioned at the forefront of the automation industry.
Whether it's refining a design for manufacturability, automating a previously manual process, or developing safer, more efficient motion control strategies, Kaufman's R&D team is focused on a singular goal: delivering the best possible results to our customers.
If you are ready to explore the possibilities, contact our automation experts today to start a conversation about your toughest manufacturing challenges.