Project Description
Our client, a large FMCG manufacturer, sought to improve the performance, consistency, and efficiency of their packaging line. The existing manual and semi-automated system was limiting throughput and causing frequent downtimes. We were tasked with designing a fully automated packaging solution using advanced PLC systems and real-time monitoring.
Timeline
Project completed in 7 weeks, from initial assessment to full deployment, without interrupting ongoing production.
Background
The client’s packaging facility handled multiple SKUs and had high demand variability. Their goal was to minimize human error, reduce production delays, and improve quality assurance. Using our industrial automation expertise, we developed a smart control system that integrated PLC-based automation, HMI panels, sensor networks, and real-time data collection.
Process
This project followed a structured approach starting with a full workflow audit and bottleneck identification. It continued through control system design, HMI prototyping, and hardware integration using PLCs, VFDs, and field devices culminating in on-site implementation, testing, and performance optimization.
Research & Planning
We performed a full system audit and mapped the entire packaging workflow. Identified bottlenecks, inefficiencies, and safety risks. Defined automation requirements based on product flow and operator feedback.
Design & Prototyping
Engineered a scalable control architecture using Siemens S7 PLCs and designed intuitive HMI interfaces. Created simulations and digital twins for system validation and operator training.
Development & Implementation
Deployed a modular control system with integrated VFDs, stepper motor controllers, and sensor-actuator feedback loops. Used Modbus and Profibus for seamless device communication. Implemented real-time diagnostics and production metrics via SCADA integration.
Solution
The resulting automation system transformed the client’s packaging line into a fast, reliable, and fully synchronized process. Through advanced PLC programming, motor control, and intuitive HMI design, the line now operates with minimal intervention, higher throughput, and real-time performance visibility.
Automated Workflow
The system now controls carton filling, labeling, sealing, and rejection via synchronized PLC logic and precise motor control.
Touch-Based Monitoring
Operators interact through custom-designed HMI panels, allowing quick adjustments, live status checks, and error alerts.
Real-Time Insights
Connected data collection platform enables tracking of production rates, error logs, and downtime analytics.
Results
The automation upgrade increased packaging throughput by 40% and significantly reduced manual intervention. Real-time diagnostics and SCADA integration enabled faster fault resolution, while the intuitive HMI design improved operator efficiency and reduced training time.
Increased Throughput
Packaging line capacity increased by 40%, with minimal human intervention.
Downtime Reduction
Machine error rates dropped by 60%, with faster diagnostics and predictive maintenance tools in place.
Operator Satisfaction
HMI usability and responsiveness received positive feedback from on-site staff, reducing training time.
