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Industrial blockless surfacing for Rx labs that want more output and less complexity.

The NEO Blockless Surfacing Line is Satisloh’s industrial blockless surfacing line for ophthalmic and optical Rx labs. By combining NEO-orbit (blockless lens generator) and NEO-flex (blockless polisher) into a modular production line, it replaces traditional block-based surfacing lines with a faster, simpler, and more efficient process, without compromising lens quality, throughput, or compatibility.

The blockless surfacing process

Simplify & Eliminate

Fewer process steps and only two machines reduce handling, labor, and maintenance effort, lower work-in-progress (WIP), and require up to 60% less lab space compared to traditional surfacing lines. At the same time, consumable costs are significantly reduced.

Eliminate process steps. Unlock performance.

NEO-orbit and NEO-flex redefine the surfacing line as a streamlined, two-machine blockless system that eliminates all non-value-added process steps, including taping, blocking, cooling, deblocking, and detaping, along with their associated machines and consumables. The result is a simpler operation and significantly faster production flow.

Faster processing = faster customer service

Fewer process steps mean less handling, less waiting time, and significantly shorter cycle times, 7 minutes tray-in to tray-out with the NEO Blockless Surfacing Line versus 50+ minutes with traditional alloy-based surfacing. 

The result: 

Faster order turnaround, and greater responsiveness to customer demand.

Increase capacity without expanding lab size 

Traditional surfacing lines require valuable floor space with tapers and blockers, cooling stations, and deblocking and detaping equipment. With the NEO Blockless Surfacing Line, all of these process steps — and the machines that support them — are eliminated. 

The NEO Blockless Surfacing Line requires as little as 56 m² / 603 f² to process 80 jobs per hour, compared to approximately 139 m² / 1496 f² for a traditional alloy-based surfacing line with similar output. That’s up to 60% less floor space, often freeing enough room to increase production capacity without moving walls or expanding the building. 

Cost efficiency built into the process

By eliminating blocking, all consumable costs associated with block pieces, alloy, glue, wax, and taping are removed. Operating with two machines instead of seven also reduces labor requirements, as fewer operators are needed to supervise and manage the line. 

Blockless processing further eliminates handling activities related to blocks, alloy, and tape, while maintaining fewer machines reduces calibration effort, micro-stops, and both periodic and reactive maintenance, resulting in lower operating costs and more predictable production. 

More sustainable surfacing process

By running fewer machines and eliminating consumables, blockless NEO surfacing reduces energy, air, and water usage while eliminating waste from alloy, glue, wax, and tape, making lens production inherently more sustainable

Full Rx product range - without compromise

Satisloh’s patent-pending Pin Vacuum Lens Reception securely supports the lens without a block, enabling blockless processing of more than 99% of typical Rx lenses. The system handles front curves up to 15D, back curves up to 18D, prism up to 10D, rotational and non-rotational designs, the full 50 - 80 mm diameter range, and all organic lens materials — using the same proven surfacing processes and delivering the same lens quality as traditional blocked production.

Trusted Satisloh surfacing technology

High-speed generating process
High-volume polishing with maximum flexibility.

In Comparison

NEO Blockless Surfacing Line compared to a traditional alloy surfacing line:

NEO Surfacing Line = 0.7 m² (7.5 ft²) per job hour capacity
Alloy Surfacing Line = 1.8 m² (19 ft²) per job hour capacity

  • Space Savings: 50%-60% savings
  • Automation Savings: 2 machines vs. 7 or more to connect

Tech Specs

ProductivityUp to 80 lenses per hour
Front curveUp to 15D, rotationally and non- rotationally symmetric front surfaces → Spheric and aspheric single vision, bifocals, trifocals, Front side & Back side progressive lenses
Back curveUp to 18D
PrismUp to 10°
Diameter50 mm - 80 mm / full support
MaterialsAll organic lens materials

All technical data subject to change without notice. Verify details with Satisloh.

NEO-orbit & NEO-flex blockless surfacing (Brochure)
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