Improve Production Efficiency
Without Increasing Headcount.
Bespoke automation systems designed to improve production stability, reduce operational risk and protect manufacturing performance — in a high-cost labour environment.
The Small Inefficiencies Are Costing More Than You Think
Manual counting. Visual checking. Operator verification. Batch confirmation. These processes happen dozens — sometimes hundreds — of times per shift on most production lines.
Each one takes a few seconds. Each one carries a margin for error. None of them appears as a major cost on a P&L. But together, across a week, a month, a year, the cumulative impact on throughput, accuracy and labour cost is significant.
The challenge is that these inefficiencies are invisible precisely because no single instance is dramatic. They’re just how the line works.
The cost shows up as:
- Higher labour hours per unit than the process should require
- Short shipments and counting errors reaching customers
- Rework and recount time absorbed into shift costs
- Management time investigating quality escapes
Production throughput limited by manual verification steps, not machine speed
Automated Counting and Verification
Comcount has been manufacturing automatic counting and verification systems for over 35 years. We have more than 1,300 systems installed at manufacturers worldwide — from small UK producers to internationally recognised names across automotive, aerospace, medical devices, fasteners, plastics and electronics.
Our systems range from standalone bowl feeder counting machines to complete, fully integrated packaging and handling solutions. They’re designed and built in-house at our Worcestershire facility, using industry-standard Siemens control systems for reliable, consistent performance.
Clients include:
- BMW
- Mercedes-Benz
- BAE Systems
- Honeywell
- Siemens
- RS Components
- Trelleborg
- Wincanton
The Impact Across Your Business
Production and Operations
- Faster throughput — counting speed no longer limits line output
- Consistent accuracy regardless of operator experience level
- Reduced stoppages caused by manual verification steps
- Better production visibility and process data
Finance and Commercial
- Lower cost per unit through reduced labour dependency
- Fewer downstream costs from counting errors and short shipments
- Fast payback — most clients recover investment faster than expected
- Scalable — systems grow with production demand
Engineering and Quality
- Integrates with existing line configurations — no redesign required
- Handles product variation and frequent changeovers
- Supports traceability and quality audit requirements
- Optional stainless steel contact parts for medical applications
Maintenance
- Stable, repeatable operation with minimal moving parts
- Clear fault identification — no black-box diagnostics
- Low running costs and minimal maintenance requirements
- UK-based service team covering the whole country
A System for Every Application
We don’t sell one product. We match the right system to your production environment — whether that’s a standalone counter, a combined counting and weighing unit, a complete bagging line, or a fully bespoke solution for components that standard equipment can’t handle.
BF Range — Automatic Counting Machines
Bowl feeder-based optical counting for most industrial and technical components. Available in single, twin-head and multi-counter configurations.
BFW Range — Counting and Weighing
Combines optical counting and weighing in one integrated unit. More flexibility for mixed-weight or high speed, high-accuracy applications.
Linear Weighing Machines
For components where weighing is the primary method. Accurate to 0.01g on appropriate ranges.
Automatic Bagging Systems
Counting or weighing machines combined with automatic baggers to produce complete packaging solutions.
Semi-Automatic Machines
Where full automation isn’t appropriate — operator-assisted systems that remove the error-prone steps while keeping human judgement in the loop.
Special Purpose Machines
For applications where standard equipment doesn’t fit. We design and build bespoke solutions from scratch.
Find Out Where Your Production Line Is Losing Time
A production efficiency review with Comcount takes around 60 minutes. We’ll look at your counting, verification and handling processes and tell you honestly where automation would create the most impact — and where it wouldn’t.
We’ll cover:
- Where manual processes are creating your biggest throughput constraints
- Which Comcount system type would suit your component and volume profile
- What a realistic payback period looks like for your situation
- Whether a standard system or bespoke solution is the right approach