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“Our best investment yet”: Automation boosts optical lab’s success in a tough market

This family-owned optical lab tripled its manufacturing capacity by investing in a fully automated production line.
Tom and Kyle Aquino in the automated production line at Dr.s’ Choice Optical Lab. The company was founded in Trenton, Ontario in 1996.

Dr.’s Choice Optical Lab is one of Ontario’s few independent, family-run optical labs. Founded in Trenton in 1996 by Tom Aquino, Dr.’s Choice offers personalized service to 30 eye care professionals across Ontario, B.C. and Saskatchewan.

“We have expanded over the past 25 years from a small in-house lab into a full-service wholesale optical lab. Our vision is to be the premier independent wholesale lens manufacturer in Ontario,” says Kyle Aquino, Tom’s son, who joined the business in 2012 and recently took over as president.

Staying competitive and thriving in a challenging industry

Optical lens manufacturing is a highly competitive industry dominated by big players who expand aggressively. Investing in technology and automation is a matter of survival for a small, independent optical lab.

Tom Aquino, executive chairman of Dr.’s Choice Optical Lab, recalls another regional optical lab that shut down a few years ago. “They asked if we wanted to buy any of their equipment. I went around, and there was nothing I could use; everything was outdated. They had stopped improving and investing in technology a long time ago. When you do that, you also stop growing and you’re eventually out of the game,” he says.

Investing in automation

To stay competitive, Dr.’s Choice invested $2 million in a fully automated production line in a brand-new facility to produce lenses for prescription glasses. It was fully operational by 2024 and has made all the difference.

Everything is automated, with minimal human intervention. This helps the company be better, faster and more precise at every stage: from cutting and shaping the lenses to coating and then polishing them.

The automated production line includes various machines, all controlled by computer systems. Employees oversee production and only intervene if needed.

Automation is the best investment we’ve ever made. We’ve been continuously upgrading, which is one of the main reasons we are still here when many other small optical labs are disappearing or struggling to survive.

Dr.’s Choice also saw value in automating lens edging, a crucial step at the end of the production process, to ensure that the lens fits perfectly into the frame. The company invested an additional $280,000 in a fully automated edging machine that cuts the lenses into frames.

Great results from top to bottom

  • 3x increased production capacity
    The new automated line helps Dr.’s Choice increase its production capacity three times, to 300 pairs of lenses a day. The company can manufacture up to 400 pairs of lenses daily while simultaneously running the old and new automated lines.

    “We are more efficient than ever,” says Kyle Aquino. “We now can handle bigger orders, serve larger clients and expand across Canada.”
  • Better lens quality
    Lenses are sensitive to handling, which can lead to scratches, errors and defects. By automating the lens production from start to finish, less handling means better lens quality.

    “By replacing manual processes with high-powered machines, we provide our customers with top-quality lenses and dependable personalized service,” says Kyle Aquino.
  • Reduced downtime
    The new production line works as an automated conveyor system. You can switch between automated and manual at every juncture, and employees can take over if the job is too sophisticated or if the machine breaks down. This reduces downtime and prevents delays.
  • Higher employee engagement
    Instead of doing manual work, employees now monitor the machine, ensuring everything is running smoothly. Their job is more engaging and provides more added value.

Customers don’t care about our problems. They don’t want to hear if the machine broke, an employee got sick, or things aren’t working. They just want their work done on time and done right. Automation helps us deliver just that. Every day.

Investing in automation since day one

1996

Tom Aquino starts Dr.'s Choice Optical Lab in Trenton, Ontario.

2000

Dr.’s Choice buys its first lens production line, producing single vision and bifocal lenses for customers throughout the province.

2011

The company buys its first digital lens production line. It can now make HD progressive lenses.

2016

Dr.’s Choice opens its anti-reflective coating facility, bringing lens coating in-house. This improves quality control and ensures faster delivery.

2019

The company starts investing significantly in automation, with new equipment and processes that streamline lens cutting, polishing, handling, and coating. Dr.’s Choice expands its network and starts serving customers across Canada.

2022-2024

Dr.’s Choice Optical Lab undertakes its most significant expansion project: renovating a new facility, installing automated production equipment and moving its entire lab to the new space.

July 2024

Grand opening of the new location. The fully automated lens production line and the latest robotic lens cutting arm are 100% operational.

Next step

Discover how to plan and execute successful industrial automation projects in your business by downloading our free guide for entrepreneurs, Harnessing the Power of Industrial Automation and Robotics.