New Line Design & Engineering
From product spec to layout, line balancing, throughput modelling, BOM, and a fixed-price proposal you can hand to your CFO.
Production Line Development · Worldwide
Production Lines Built to Hit Your Throughput
GTS Worldwide designs, automates, integrates and optimises production lines for manufacturers worldwide — whether you're launching a new product, expanding capacity, retrofitting legacy equipment, or chasing a higher OEE on a line that's already in service.
- 200+Lines deployed worldwide
- 30%+Avg OEE uplift on retrofits
- 8–16 wkTypical line build & commission
EngineeredThroughput · OEE · Quality
Capabilities
Line DesignAutomation & RoboticsRetrofits & ModernisationOEE OptimisationIndustry 4.0
From a single station to a fully automated line
Our production-line work covers the full lifecycle — concept, engineering, machinery, automation, installation, commissioning and ongoing optimisation. One contract, one accountable engineering team.
Automation & Robotics Integration
PLC, SCADA, robotics, vision systems, conveyors and AGVs unified into one control architecture — in-house, not subcontracted.
Retrofits & Modernisation
Replace obsolete controls, add safety, integrate Industry 4.0 sensors and extend the life of legacy lines without ripping them out.
Debottlenecking & OEE Uplift
Cycle-time analysis, MES data review, and targeted upgrades that move availability, performance and quality numbers in the right direction.
NPI & Line Conversion
Convert existing lines for a new product, scale a prototype process to series production, or stage a tooling changeover for a new SKU mix.
Installation, Commissioning & Validation
On-site mechanical and electrical installation, pneumatic / hydraulic hook-up, FAT/SAT, calibration, ramp-up support and operator training.
From KPI workshop to first good part
A milestone-driven process that gives engineering, operations and finance the visibility they need.
- 01
Discovery & KPI Workshop
We sit down with your operations and engineering team to lock in throughput, OEE, quality and CAPEX targets — before a single drawing is made.
- 02
Concept & Simulation
2D / 3D layouts, line-balancing models, and digital-twin simulation where the cost of being wrong justifies it.
- 03
Detailed Engineering
Mechanical, electrical, pneumatic, hydraulic, software and safety design packages — ready to procure against.
- 04
Machinery & Component Procurement
We source new, used or refurbished equipment from our global network. Inspection, logistics, customs and warranty are managed for you.
- 05
Installation & Integration
On-site mechanical and electrical assembly, control integration, SCADA/MES connection, network and safety integration.
- 06
Commissioning, Ramp-Up & Training
FAT, SAT, calibration, performance run-off against your KPI targets, hypercare and operator training in your team's language.
Production lines for every kind of plant
Whether you make precision metal parts, packaged food, plastic components, or printed materials, we've engineered, sourced and commissioned it before.
Metalworking
CNC machining cells, transfer lines, welding cells, sheet-metal lines, deburring and finishing automation.
Automotive & Tier Suppliers
Robotic welding cells, assembly lines, paint shops, stamping cells and sub-assembly transfer lines.
Food & Beverage
Filling, capping, bottling, dairy, bakery and meat lines, sterilisation, frozen and ready-meal packaging.
Plastics & Rubber
Injection-moulding cells, extrusion lines with downstream, blow-moulding and thermoforming lines, recycling.
Packaging & Printing
Flexo and offset printing, corrugating, folding-carton, labelling, end-of-line cartoning and palletising.
Woodworking & Furniture
Panel processing lines, edge banding, CNC routing, lacquering, and assembly lines for furniture and joinery.
Recycling & Circular Economy
Sorting, shredding, washing, pelletising and granulating lines for plastics, metals, paper and e-waste.
Textiles & Nonwovens
Spinning, weaving, knitting, dyeing, finishing and converting lines for technical and apparel textiles.
Pharma & Cosmetics
GMP-compliant filling, capping, blistering, inspection and packaging lines for OSD and liquid forms.
Built around your numbers, not our catalogue
Most line projects fail because automation, machinery and controls come from three different suppliers who don't talk. We do all three under one roof.
Throughput-first engineering
Every line is designed backwards from your output, OEE and quality targets — not from a stock layout we like to repeat.
Vendor-agnostic machinery
We pick the best machine for each station from a global pool of new, used and refurbished equipment, not from one OEM's catalogue.
Real automation depth
In-house expertise across PLC, SCADA, MES, robotics, vision and Industry 4.0 sensors — no subcontracting the hard parts.
Retrofit-friendly
Where it makes sense, we extend the life of your existing line instead of forcing a full replacement. CAPEX you can defend.
Three regional hubs
Offices in the USA, Germany and the UAE keep us close to your site, your timezone and your customs regime.
Long-term service
Spare parts, preventive maintenance, performance audits and upgrade roadmaps protect your line for the next decade.
Frequently asked questions about production line development
Quick answers to the questions our clients ask most often when scoping a new or retrofitted production line.
What's the difference between "Build Your Factory" and "Production Line Development"?
"Build Your Factory" is a turnkey program for greenfield plants where we deliver an entire factory under one contract. "Production Line Development" is focused on a single line or a group of lines — new builds, capacity expansions, retrofits, or NPI conversions inside an existing plant. Most of our customers start with line work and scale up over time.
Can you upgrade an existing line, or only build new ones?
Both. We do greenfield line builds and we do retrofits / modernisations on existing lines — including obsolete-controls replacement, automation upgrades, vision-system additions, MES integration and safety upgrades.
How long does a typical production line take to commission?
A focused line build typically runs 8 to 16 weeks from contract to first good part. Larger automated lines with custom robotics and MES integration take 4 to 9 months. We share a milestone schedule before kick-off.
Do you handle PLC, SCADA, MES and robot integration in-house?
Yes. Controls and automation are core competencies, not subcontracted. We work with all major brands — Siemens, Rockwell / Allen-Bradley, Beckhoff, Mitsubishi, Omron, Schneider, ABB, KUKA, FANUC, Yaskawa — and integrate with your existing MES / ERP.
Can you simulate the line before we commit?
Yes. For lines where the cost of being wrong justifies it, we build digital-twin simulations to validate throughput, line balancing, buffer sizing and operator workload before procurement begins.
Can you support a new product introduction (NPI) on an existing line?
Yes. NPI work is a regular request — tooling changes, fixture redesign, vision-system reconfiguration, recipe management, validation runs, and documentation updates. We can also scale a prototype process up to series production.
Which industries do you build production lines for?
Metalworking, automotive, food and beverage, plastics, packaging, woodworking, recycling, textiles and pharma. If your output is countable on a takt clock, we've probably built a line for something similar.
Do you provide line balancing and OEE optimisation?
Yes. We run on-site cycle-time studies, MES data analysis, and targeted upgrades to lift availability, performance and quality — the three components of OEE. On retrofit projects, our customers typically see double-digit OEE gains.
Do you offer service contracts after handover?
Yes. We offer preventive maintenance contracts, on-call repair, spare-parts supply, retrofit and upgrade services — for lines we've built, and for legacy lines from other suppliers.
How do I get started?
Visit our Contact Us page or call +1 305 951 7825 (Americas) or +971 58 579 4328 (Europe / Middle East). One of our line engineers will reply within one business day with a structured questionnaire to scope the project.
Free ConsultationTell us about the line you need.
Tell us about the line you need.
We'll respond within one business day.
Share your product, target throughput, OEE goal and a rough timeline. One of our line engineers will follow up with feasibility notes, ballpark costing and the next steps.
- No obligation, no cost — just an honest read on feasibility.
- Confidential — we'll sign an NDA before any technical exchange.
- Direct to engineering — you talk to people who'll actually build it.
GTS Worldwide — production line development, automation, robotics integration, retrofits, OEE optimisation, NPI and line commissioning for manufacturers worldwide. Serving metalworking, automotive, food & beverage, plastics, packaging, woodworking, recycling, textiles and pharmaceutical industries from offices in Miami Beach, Darmstadt and Dubai. New lines, capacity expansions and modernisation of legacy equipment under one accountable engineering partner.