pāco manufacturing® was awarded projects from a new customer involving a new industry to us, namely The Cooperage Industry.  Our customer contacted us on a request to design and build equipment very similar in operation to their existing production equipment for their new cooperage plant. However, our new designs incorporated many improvements for additional precise handling of the product, improved operator ergonomics and safety, added structural integrity and replaceable tooling for decades of production, along with operator and maintenance friendly improvements.  The current processes of making cooperage barrels which have been developed from proven old world techniques were implemented into modern machinery processes with the inclusion of PLCs (programmable logic controllers) and touch screen interface (HMI) operator controls.  The scope of the project covered the design and manufacturing of five (5) new pieces of equipment:

Bilge Hoop Puller Machine
Bung Drill Machine
Air Water Test Machines
Air Test Stations
Barrel Cradle Station


Engineering Evaluation

  • View existing equipment in operation
  • Thorough study and measurements
  • Customer defined specifications & requirements

3D Modeling

  • Conceptual Design
  • Mechanical Design
  • Safety and Guarding Designs
  • Pneumatic Designs
  • Hydraulic Designs
  • Electrical Controls Design
  • PLC & HMI Programming
  • Animated 3D Conceptual Presentation showcased for Customer Approval

Manufacturing Design Packages

  • Machine Assembly Drawing
  • Itemized BOM’s
  • Sub-Assembly Drawings
  • Part Fabrication Detail Drawings with Machining Tolerances


  • Carbon Steel & Aluminum Materials
  • Steel Structural Tubing
  • MIG Type Welding
  • TIG Type Welding

Machining Components

  • 4-Axis CNC Millling
  • CNC Lathe
  • Paint, Black Oxide, Plating, Anodizing & Heat Treat Hardening as needed


  • Sub-Assemblies
  • Installation of Motors, Actuators, Pneumatic & Hydraulic Valves
  • Manually Set Actuator Speeds, Flow Controls & Stop Positions
  • Pre-debug Machine Operations in a one-at-a-time with each moving operation

Electrical Controls

  • Assembly & Wiring of Electrical Controls
  • NEMA12 Enclosures
  • Category 3 Safety Specifications
  • 24 VDC I/O
  • Install PLC & HMI Programming


  • PLC & HMI Testing
  • Dry Cycle Testing (machines tested without product)
  • Complete Run Cycle Testing (machines tested with product)
  • Fine-Tune Mechanics & Controls
  • Optimize Sequence & Production Cycle Rate
  • Customer Approval

Plant Installation

  • Coordination of Installation with Company
  • Installation of Guarding & Safety Components
  • Rigorous Factory Acceptance Testing
  • All Possible Scenarios checked for Proper Operation & Fault Recovery