How Automated Dip Tanks Improved Quality & Efficiency for a Leading Manufacturer
In many manufacturing environments, precision dipping is a critical step in ensuring product performance and longevity. When parts must be submerged for exact durations—sometimes just seconds off can compromise the entire batch—businesses often struggle with the limitations of manual dip tanks. This was exactly the challenge faced by one of Deco Manufacturing’s customers before partnering with us for a fully automated solution.
The Challenge: Manual Dipping Led to Costly Variability
The customer produced a variety of parts that each required a unique dip time. Their existing workflow relied on workers manually lowering and raising components into a dip tank. While functional, this method created several problems:
Inconsistent submersion times
Workers frequently dipped parts too long or too briefly, unintentionally causing defects.Quality control failures
Inaccurate timing led to product failures, rejected batches, and expensive rework.Dependence on operator attention
Breaks, distractions, and shift changes increased the risk of human error.
Manual dipping simply couldn’t deliver the repeatable, precision-controlled results the customer needed to maintain their production standards.
The Deco Solution: PLC-Automated Dip Tanks Built for Accuracy
Deco Manufacturing solved the problem by designing and delivering automated dip tanks equipped with programmable PLC controls. These systems were engineered specifically for the customer's unique process requirements.
What Makes Our Automated Dip Tanks Different?
✔️ Precise timing for every part type
Each dip tank is programmed with custom lower/raise cycles matched to the customer’s exact specifications.
✔️ Zero reliance on operator timing
Workers no longer need to monitor the process manually—reducing errors and increasing throughput.
✔️ Consistent quality, every time
Automated cycles ensure each part receives the proper submersion duration, eliminating variability and dramatically improving quality control.
✔️ Productivity even during breaks
Even when employees step away, the system performs flawlessly, maintaining optimal timing and workflow.
The result is a modern, efficient, and dependable dipping process that supports the customer’s long-term manufacturing goals.
Impact: Higher Quality, Lower Risk, Better Process Control
After integrating Deco’s PLC-automated dip tanks, the customer saw immediate improvements:
Eliminated quality control issues caused by human timing errors
Significant reduction in product failures and rework costs
Improved consistency across shifts and operators
Streamlined workflow and increased production reliability
By automating a previously inconsistent step, the customer transformed a critical bottleneck into a controlled, predictable, and high-performance part of their manufacturing line.
Why Manufacturers Choose Deco for Automation Solutions
Deco Manufacturing specializes in helping companies modernize their production systems through custom automation, precision-controlled equipment, and engineered manufacturing solutions. Whether you’re facing challenges in consistency, quality, throughput, or operator variability, Deco provides solutions built around your exact needs.
If your process relies on manual dipping—or any workflow vulnerable to human error—an automated system may be the key to unlocking higher efficiency and better product performance.
