I. Structure of the Complete Line Quote
The quote for a complete line comprises three main components. According to industry data, quotes for custom production lines typically follow a “basic equipment cost + system integration cost + technical service cost” structure: basic equipment costs account for 55%–65%, calculated by aggregating the unit prices of core machinery (conveyor lines, robots, and specialized equipment);
system integration costs account for 25%–30%, covering PLC programming, HMI development, sensor wiring, and safety interlocks; and technical service costs account for 10%–15%, covering solution design, factory acceptance testing, on-site installation and commissioning, and operator training.
II. Mechanical Core Components
What does the mechanical core include? According to industry data, a complete assembly line typically includes a conveying system, robotic arm modules, automated inspection stations, a control system, and a packaging unit.
Conveying systems (roller or belt conveyors) account for approximately 15%–20% of the cost;
a single six-axis robot costs around 80,000–150,000 RMB, with a typical line requiring 3–5 units; and AOI (Automated Optical Inspection) stations—especially imported brands—command higher unit prices. The quotation list should itemize the machine frames, tooling plates, conveying systems, robots, and inspection stations separately.
III. Electrical and Software Components
What do the electrical and software components include?
According to industry data, electrical control systems account for 15%–20% of the total line cost.
This includes PLC programming, HMI interfaces, data acquisition, and MES integration—areas where technical complexity and cost proportions are rising. The sorting electrical control system encompasses wiring for conveyor roller beds and robot end-effector cameras, power cables, cable trays/conduits, electrical control cabinets, electrical components, sensors, and PLCs (including programming). Electrical ancillary costs often represent a significant portion of “hidden” expenses.
IV. Installation and Commissioning Services
Installation, commissioning, and technical services.
Industry data indicates that installation and commissioning account for 5% to 10% of the total cost, covering on-site installation, wiring, commissioning, training, and trial runs; travel expenses increase significantly for remote projects. Technical service fees include solution design, Factory Acceptance Testing (FAT), on-site Site Acceptance Testing (SAT), and operation training. “Turnkey” prices are typically 20% to 40% higher than “bare machine” prices (which exclude installation and commissioning);
always clarify whether installation is included before signing the contract.
V.
Avoiding Pitfalls in Cost Itemization
Itemized costs and hidden fees. Based on industry experience, when reviewing a quotation, you must verify the following: equipment frames, tooling plates, electrical control systems, sensors, safety guarding, on-site installation and commissioning, personnel training, and transportation costs. Common hidden fees include transportation, hoisting, foundation work, electrical infrastructure, commissioning, travel, spare parts, training, and taxes.
Charging extra later for requirements already confirmed in the initial proposal constitutes a malicious price hike, whereas charges for new requirements added after signing are legitimate additional costs—ensure every item is explicitly written into the contract.
Conclusion
What does a quotation for a complete non-standard assembly line include? The answer is “three major components plus nine detailed items”: basic equipment costs at 55%–65% (frames, conveyors, tooling, robots, inspection stations) + system integration costs at 25%–30% (PLC programming, HMI, sensor wiring, safety guarding) + technical service fees at 10%–15% (solution design, factory acceptance, on-site installation and commissioning, operation training). Additional costs cover transportation, packaging, hoisting, electrical infrastructure, taxes, and after-sales maintenance (calculated at 3%–5% of the equipment value).
In accordance with industry practice, suppliers should be required to provide itemized quotes that clearly specify brands, model numbers, and pricing inclusive of taxes and shipping; “turnkey” prices typically run 20%–40% higher than the cost of the standalone equipment alone—the more detailed the quotation, the fewer additional costs will arise later.
A comprehensive quote for an entire production line must also incorporate safety features (such as fencing, light curtains, and interlocked door systems), acceptance criteria, and warranty terms.
