QUALIFICATIONS
- BTech (Mech) – 2019
SOFTWARE
Mechanical CAD Software
- AutoCAD
- Inventor (Autodesk)
- SolidWorks (Dassault)
PDM/PLM Software
- Inventor Vault (Autodesk)
- SolidWorks PDM (Dassault)
Gene Prato
TEAM LEAD
Skills Overview
Gene is a highly driven engineer with extensive experience in machine building, stemming from designing complete product handling lines. Gene’s expertise encompasses the entire project lifecycle, from conceptual design to gain customer buy-in, to the installation of machinery at customer sites, accompanied by all necessary documentation. Possessing a deep understanding of machinery, Gene excels at problem-solving and devising practical solutions to ensure optimal machine performance.
- MATERIALS HANDLING EQUIPMENT – Gene possesses expertise in designing and constructing rotary rinsing, filling, and capping machines, as well as conveyors and end-of-line machinery. This background provides Gene with a comprehensive understanding of developing fast-moving production lines.
- FOOD HANDLING EQUIPMENT – Gene’s proficiency extends to designing machinery that meets stringent hygienic standards. This includes building machines for pharmaceutical product filling and designing dairy industry filling machines to extend product shelf life. Gene knows the codes and standards necessary for building machinery suitable for aseptic environments.
- ROBOTICS & AUTOMATION – Gene’s background includes working with Cobot robots. This experience includes designing an end effector for a Reynolds Group Limited customer and participating in two distinct projects for the same group. These projects involved designing the mounting and positioning of Cobots and using RoboDK software to determine the Cobots’ operational positions. This work significantly expedited the programming stage of these projects by providing clear guidance to the automation team.
- DESIGN FOR FABRICATION & USE – Gene has successfully completed projects in production line machinery and ancillary equipment. Working closely with manufacturing and fabrication teams at different stages of the production process has enabled Gene to develop designs with a focus on ease of fabrication and user-friendliness. This experience ensures that Gene’s designs are not only efficient but also practical for end-users.
PERSONAL STATEMENT
I enjoy engineering as I have always been fascinated by the way things are built and put together. With working in engineering, you can be a part of building the machines. It is always such a great feeling seeing your machine go from an idea to a design and on to a working model. I’m a keen surf ski paddler and represented South Africa when I was younger.
Project Experience
AEROSPACE ENGINEERING
Designed large steel structures taking from concept to 3D CAD modelling and detailed manufacturing drawings. Worked on improving mechanical designs by optimising for manufacturability. Generated complete manufacturing drawing packages, including part, assembly, and fabrication drawings with GD&T. performed structural Finite Element Analysis (FEA) to validate mechanical integrity and ensure components met or exceeded load and safety requirements.
NECK HANDLING LEVEL FILLER
Designed a Neck handling filling machine. The machine was a 36 head water rinser, 40 head bellow level filler, 10 head capper. The machine had to be a single unit with gears synchronizing the machine. The machine had to deliver 250 filled and capped bottles a minute.
NON-STOP BOTTLE LABELLER
Design a labeller machine for a pharmaceutical company that would reduce to amount of down time on the machine for the replacement of a completed label reel. The line needed to run at 200 units a minute. The machine also has a Pharma coder as well as a camera inspection to ensure the label had the Pharma code and the label was applied correctly.
ROTARY NET-WEIGHT PUFFER INSERTER CAPPER
Designed a fully automated 12 head net-weight filler ,4 head puffer inserter, 4 head servo torquing capper. This machine was built for the health and built industry. The machine was filling products from miracle water to acne cream. The machine run bottles from 50ml to 500ml and ranged for 100 to 20 units per minute. The machine had to be fully hygienic.
ROTARY SERVO CAM SERVO TORQUING TRIGGER CAPPER
A rotary machine design to pick up a spray bottle cap from an infeed system and place and screw the cap on to a set applied torque. The machine also had a servo cam which would allow the cam profile used in capping to be adjust for different cap sizes. The machine would operate at 60 units a minute.
VERTICAL FORM FILL & SEAL MACHINE
Designed a fully automated machine to form a sachet that would then be filled with a flowmeter to deliver the set amount of alcohol and be sealed closed. This machine filled sachets from 10ml up to 250ml at 25 units a minute.
PUNCH TOOL DESIGN
Designed a Punch Tool Set for punching a hole in the side of fridge inner linings. Off the shelf punches were not suitable because the holes were too close together and there wasn’t enough space on the tool face. Selectable punches, located on the tool face, were required to allow for different product requirements, design iterations, and eliminate the need for new tool sets to be designed in the future.
VERTICAL FORM FILL & SEAL MACHINE
Designed a fully automated machine to form a sachet that would then be filled with a flowmeter to deliver the set amount of alcohol and be sealed closed. This machine filled sachets from 10ml up to 250ml at 25 units a minute.
“Gene is great to work with. He stays on task well, but without putting his blinkers on—he keeps on top of what else is going on in the department so he can operate accordingly. He's happy to get stuck in (has been helping out on the shop floor a fair bit) and has a great attitude overall. He's also communicated really well with the rest of the team.”
Semi Automated Finished Board Labelling Machine
Took an exciting design that only had drawings from the 2000s and modelled the machine to be remanufactured. Brought the machine up to current health and safety standards. Added in the new features that had been sold with the machine, additional drive row, last row disengagement unit when running shorter boards. Supplied new assembly and manufacturing drawings for the updated machine. Did the technical documentation for the machine. Involved in the full life cycle of the project.
Automated Pallet Strap Labelling
Designed the full automated machine and the new end effector for the UR5 Cobot Robot. The end effector needed to be able to pick up a flat printed label and fold the label back on itself, over some pallet strapping. The end effector needed to be light enough to be fitted to the end of the UR5 which could only take a payload of 5kg. The robot had to be able to apply the label to the front face of the pallet and the side of the pallet. The project path for the UR5 was done using RoboDK and supplied to the Automation Team to get the waypoints. Involved in the full life cycle of the project.
Automated Pallet Labelling
Updated the configuration of the labelling unit to be able to reach the desired labelling positions without having to use any new parts in the configuration. Got the projected path of the UR5 on RoboDK and supplied the path to the Automation Team the write the program for the machine.
Test Sample Labelling
Added safety guarding to an existing machine to ensure it meets the Health and Safety standards while keeping the machine accessible. Helped to run and test the machine to ensure it meets the customer buyers specifications.
Robot seam welder feasibility study
Fletchers wished to improve the capacity, finish quality, and safety of an existing welding process. They had a potential supplier, but needed a feasibility study done to prove the proposed line would be fit for purpose. Caliber was responsible for creating a new factory layout, creating a project charter document, and liaising with the supplier and contractors. We also developed project plans, project timelines, time study, and cost of running the current system vs the proposed system. This got the project to the point of being ready for CAPEX approval.
Redbud feasibility study
One of Fletchers existing machines had an outdated obsolete HMI and PLC. They had an old quote to upgrade or replace the components, however it was out of date so they tasked Caliber with doing a feasibility study. The Caliber engineer gathered information, liasied with the manufacturer, and presented Fletchers management with a project charter document. This outlined the business case, and estimated timeline and project cost. On review, it was decided that it was too expensive to replace or upgrade the machine. A second option was presented, to re-code the machine. Caliber defined the scope of work to be done and leasing with the potential programs to be able to re-code the existing machine to get estimated quotes for the machine.
Stapler machine relocation
Fletcher Steel identified that the existing configuration of their machinery did not meet the ASNZ-4024 standard, posing a potential safety risk. To urgently address this issue, they needed a business case and feasibility study to be conducted to secure Capex approval. They didn’t have a capacity within their own team to do this, so asked Caliber to help move the project forward. After careful consideration, the project charter was developed, and Capex was granted. Caliber took on the responsibility of project management, coordinating with various contractors and overseeing site work. As a result of this project, the safety risk was successfully mitigated, ensuring compliance with the ASNZ-4024 standard.
