How We Develop A New Device For Industry 5.0

The process of creating a new device always starts with a client’s issue related to its production process. This brings our team to collect ideas and knowledge to find the best solution that brings advantages to the client.

Nowadays, industries driven towards innovation, are gradually starting to shift their conception of production from Industry 4.0 to Industry 5.0, where a complete customization of the product is at the center of this Fifth Industrial Revolution. Caronte, being already part of Industry 5.0, exclusively designs intelligent devices on the basis of client’s needs; these devices are integrated in the production in order to intelligently improve manufactory operations thanks to the use of new technologies, such as: Machine Learning, Big Data Analysis, Neural Networkds, Artificial Vision, Artificial Intelligence, and so on.

But how does Caronte make a new device for Industry 5.0 starting from scratch?
Let’s find out.


In this first phase, the client approaches us by presenting a problem related to its production process. This is followed by a detailed visit of its industrial plant and where, in particular, he is experiencing a problem. It is essential for our team to inspect the site and know exactly how production works, from start to finish, in order to provide the best service while finding the right solution. Eventually, the client assigns us the task of finding our best solution based on our knowledge and skills.


In this second phase, we start to think about what type of technology may come to help in order to solve the client’s problem. After having identified the technology, we put down ideas on the practicality of this device, while and our engineers begin to design the intelligence behind it, where all the magic happens.

Figure 1. Sketches from brainstorming.


In this third phase, our engineers, after having collected enough information regarding the aim of this device and where it needs to be installed, start to compose the technology that will make the device work intelligently and on the basis of what the client asked. The heart of these devices are their softwares: this phase, in facts, requires much more time than the others as our engineers develop a customized software from scratch. This software will help both the plant’s operators (they interface with the real time results of device installed on the production line), and the whole intelligent automation process (this allows to always have a standard production).


Once our engineers have developed the technology and the software of the new device, it is time to design the prototype in detail, respecting of a series of parameters, as: the size of the internal electrical parts, food contact materials, CE certifications, the position inside the plant where it will be installed, and more. Usually in this phase, we come to make a lot of adjustments and changes to the protype until we finally observe that the last design works perfectly to the client’s needs.

Figure 2. First draft of the device.

Figure 3. Final draft of the device.

Figure 4. Customization of the device.


After all the calculations and technical measurements, we finally step into the real making of the new device: the handmade construction. This is a step that our team take very seriously since all our products are made in Italy and customized upon the client’s necessities. By having such a peculiar cure while handmading our devices, we increase their quality and cure of the details.
Since a lot of our devices are intended for food industries, we use materials that can only be used in contact with food (MOCA).


All of our devices are customized, not only in the outcome, but also in the equipment. In facts, we include the client company’s name/logo on the electrical parts, on the external case and on its dedicated software. We do this because we want our client to feel comfortable with these new technologies.


The last phase sees intense weeks of technical tests in our laboratory. During these tests, we verify its functioning at 360° and fix any problem that may come up. The final before delivery are mostly strees tests, both on the resistance of the equipment and on the electrical parts that are contained in it. When our engineers are completely satisfied by the outcome of the test, we proceed with the delivery to our client’s industrial plant. Once installed, the new device undergoes to further tests and only once all the check list has been completed, we install our customized software on their production computer and connect the device to it. Generally, we also carry out intensive courses to production operators, so that they undestand how the device and the software interact have become a new part of their process.

Figure 5. The device set to technical tests.

Mini Phobos - Caronte Consulting

Figure 6. Final device.