For over two decades, PCE Automation has worked alongside some of the world’s largest ophthalmic companies, building a reputation for excellence in the design and delivery of automation solutions for contact lenses, intraocular lenses, and the wider ocular health sector.
This expertise has resulted in a proven track record and the formation of long-standing partnerships throughout the ocular industry:
“We have worked with PCE for over 20 years, from initial R&D solutions to manufacturing custom automation production lines that have been repeated in many of our global manufacturing sites.
When it comes to new technologies and innovation, we are always confident PCE Automation will deliver a system to our full requirements.”
Ocular Client – Senior Leadership Member
A QUALITY-DRIVEN AUTOMATED PROCESS
Our expert team brings extensive knowledge of complex ocular automation processes. This experience has enabled us to develop a 12-step approach to our automated solutions for manufacturing contact lenses. Supported by clean factory floor assembly areas, we are equipped to handle clinically sensitive contact lenses and other ocular health products to meet your requirements and needs.
12-STEP APPROACH: PROVEN AND PRECISE
We implement a carefully thought-out process that blends precision engineering with strict quality control to ensure that quality is maintained throughout the entire contact lens manufacturing process.
It begins at the moulding stage, where the original cast mould is removed from the injection moulding machine and prepared for lens formation. A liquid monomer is then carefully introduced into the mould before being sealed via press-fit or heat stake welding.
Once closed, the mould moves into the curing phase. Here it passes beneath high-intensity LED UV light on a transport system with complete part traceability, allowing the monomer to cure and form the contact lens. After curing, the mould is opened and the upper mould is mechanically removed and discarded, while the newly formed lens remains attached to the lower mould half. This controlled demoulding step protects the delicate lens surface at a critical moment in the process.
The lens is then gently separated from the remaining mould through a delensing process that can be carried out using dry or wet techniques, depending on the material and design. Following removal, the lens is transferred into a hydration bath, where it sits in a liquid solution for a defined period. This hydration step is essential, allowing the lens to achieve its final softness and optical properties.
Quality assurance plays a major role from this point onward with each hydrated lens being inspected to detect any imperfections such as scratches, bubbles, or surface defects. Only lenses that meet strict quality standards move forward. Approved lenses are then carefully handled and placed into transport trays or nests to maintain their shape and cleanliness as they head towards primary packaging.
Packaging is designed to preserve sterility and product integrity. Each lens is placed into an individual blister pack and filled with a precise dose of saline solution. The blister is then sealed with foil using heat, creating a secure, tamper-proof package. Unique identification data is laser-etched onto the foil and inspected to ensure clarity and traceability.
In the final stage, the sealed blisters are grouped and placed into secondary cartons, ready for distribution. From mould to carton, every phase of the contact lens manufacturing journey is tightly controlled to ensure that the finished contact lens is up to your regulatory standards.
WHY PCE?
By applying our tried and tested approach that has been refined over decades, you can trust us to deliver reliable results. Each stage of the approach is designed to ensure product quality and regulatory compliance while maximising production efficiency.
Our automated systems also deliver significant operational benefits. Labour costs are reduced, manufacturing time and throughput is increased as well as minimising variability caused by manual handling. Integrated inspection into our process ensures traceability and compliance, while precision handling protects the delicate lenses throughout manufacture. The outcome of all of this is a satisfied customer and satisfied end user with the quality of product they have received.
Importantly, our solutions are fully scalable. If you do not require a complete end-to-end automated line, individual machines or modules can be seamlessly integrated into your existing manufacturing environment to suit your needs and requirements. This flexibility allows you to automate at your own pace and future-proof operations while maximising return on investment.
THE FUTURE OF OCULAR
The ocular sector continues to evolve at pace. Growing global demand, increased product complexity, tighter regulatory requirements, and rising expectations around quality and consistency are reshaping how contact lenses and ocular health products are manufactured.
How do you maintain speed while improving quality?
How do you scale production without compromising precision?
How do you find new solutions while managing risk?
Innovation is at the heart of how we answer these questions. By combining deep industry knowledge with advanced automation technologies and decades of automation experience we help ocular manufacturers stay ahead – developing smarter, more efficient production systems that are ready for the future.
BRING YOUR VISION TO LIFE
Working with you from concept through to commissioning we can engineer the future together. PCE is committed to being your partner in finding and implementing your automated projects, bringing decades of experience and engineering excellence to every project. Whether you are launching a new product, upgrading an existing process, or scaling global manufacturing operations, we are here to help bring your vision to life.
Get in touch with our in-house experts and we’ll engineer a solution together: enquiries@pceautomation.co.uk
English 
Spanish