EMERALD™ Indexed Automation Platform
Precision Assembly, Printing and Verification on One Integrated Platform
The EMERALD™ platform is AAE's robust automation solution for manufacturers requiring precise indexed motion and fixed-cycle production. Designed around proven indexing technology, EMERALD combines assembly, printing, inspection, testing, and verification into a single integrated manufacturing platform.
Unlike conventional production lines that rely on multiple stand-alone machines and manual transfer steps, EMERALD synchronizes all critical manufacturing processes within one controlled automation environment. The result is a highly flexible, scalable, and reliable solution for manufacturers seeking efficiency, quality, and future growth.
Why EMERALD?
One Platform. Controlled Production Flow.
The optimal EMERALD configuration is determined by three key factors: the number of product variants, the number and sequence of process steps, and the required production output. Whether the application involves assembly, ultrasonic welding, printing, inspection, testing, or a combination of these processes, EMERALD can be configured to match both current manufacturing requirements and future expansion plans.
Depending on the application, EMERALD is available as either a Round Indexing or a Linear Indexing solution.
For compact manufacturing cells with a limited number of process stations, Round Indexing provides an efficient and cost-effective solution. These systems are particularly suitable for low- to medium-volume production, pilot manufacturing, and products in the early stages of their lifecycle. Available with both cam-driven and servo-driven indexing technology, Round Indexing platforms offer excellent positioning accuracy, predictable cycle times, and a compact machine footprint. Typical positioning accuracy is ±0.05 mm, depending on the diameter and radius of the indexing table.
As product complexity increases, additional process stations may be required for assembly, inspection, verification, testing, or packaging operations. In these situations, EMERALD can be configured with AAE's Linear Chain System (LCS), a high-precision linear indexing platform designed for longer process sequences and maximum flexibility.
The LCS precision chain combines the scalability of a linear architecture with the repeatability required for demanding automation processes. Standard LCS configurations achieve a positioning accuracy of ±0.10 mm, while an enhanced cam-driven positioning system can further improve accuracy to ±0.02 mm. This allows manufacturers to combine long process sequences with precision assembly, inspection, and testing operations without compromising cycle time performance.
Its spring-loaded precision chain design ensures stable positioning throughout the machine lifetime while preventing chain elongation over time. Manufactured from precision-machined aluminum links with a 125 mm pitch, the LCS can be configured with more than 100 links, enabling highly complex manufacturing sequences within a single integrated automation platform.
Whether configured as a compact rotary system or an extended linear platform, EMERALD delivers the same integrated process capabilities, manufacturing intelligence, and quality assurance architecture, allowing manufacturers to scale production without changing their automation philosophy.
One Platform. Controlled Production Flow.
EMERALD integrates part feeding, orientation, surface treatment, printing, UV curing, inspection, assembly, leakage testing, ultrasonic-, laser-, spin welding, labeling, capping, inspection, filling, crimping, testing, buffering and unloading into a single indexed-motion production platform.
Benefits
Fixed and predictable cycle times; excellent process control; reduced factory footprint; lower labor requirements; improved product quality; higher OEE; modular and scalable architecture.
Designed for Complex Product Manufacturing
EMERALD is specifically developed for products that are non-round, non-symmetrical, or require controlled positioning throughout the manufacturing process.
Typical applications include:
Valves, Injectors, Medical cassettes, Pumps, Cups & Dials, Cartridge holders, Counting ring assemblies, Custom engineered products
Where continuous-motion solutions are often selected for the highest-volume applications, EMERALD provides the flexibility to support product variation, process complexity, and evolving production requirements.
The platform grows with your manufacturing needs and can be configured for both medium- and high-volume production environments. Depending on the application, EMERALD can be configured with 2-, 4-, or 6-lane production architectures, delivering outputs of up to 420 parts per minute. Typical cycle times range from 0.7 to 2.0 seconds, depending on product complexity, process content, and machine configuration. This modular approach allows manufacturers to increase capacity while maintaining fixed-cycle production, process stability, and repeatable product quality.
Inline Verification: Quality Built Into Every Step
EMERALD is built around a simple philosophy:
The machine does not only perform the process — it proves the process was performed correctly.
Every critical manufacturing step is continuously monitored and verified in real time, ensuring process stability, product quality, and full traceability throughout the production cycle.
Examples include:
Feeding verification, product presence detection, product orientation confirmation, position and indexing verification, print inspection, assembly force monitoring, functional testing, leak testing, vision inspection, product tracking and rejection management
By identifying deviations immediately, EMERALD prevents defects from progressing through the manufacturing process, reduces scrap, and enables continuous process optimization based on real-time production data.
Digital Manufacturing Ready
Every production event generated by EMERALD can be recorded, time-stamped, and linked to individual products, batches, or production orders.
The platform integrates seamlessly with existing:
MES systems
SCADA environments
Factory analytics platforms
SPC systems
ERP-connected manufacturing environments
For manufacturers seeking a rapid path toward digital manufacturing, AAE can provide a dedicated Edge Data Platform that collects, stores, visualizes, and analyzes machine-level production data directly at the source.
This enables complete production traceability, real-time performance monitoring, predictive maintenance strategies, and actionable manufacturing intelligence from day one.
Partner with AAE
For more than five decades, AAE has been developing high-performance automation systems for the medical device industry.
The CASCADE platform combines our expertise in continuous-motion engineering, printing technology, assembly automation, and digital manufacturing into a single scalable solution for syringe production.
Interested in optimizing your manufacturing process?
Contact our team to discuss how EMERALD can be configured for your application.