Monitoring Packaging Line with ESP32 PLC
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SUMMARY
A food packaging company needs to monitor and store the production process of its packaged products.
The company requires a solution to monitor:
✅ the quantities produced
✅ the product batches
✅ the batch groupings per case
✅ the barcodes of each primary packaging, and
✅ its grouping in cases (secondary packaging)).
IMPLEMENTATION OF THE MONITORING SOLUTION
The engineering firm that works regularly with the company proposed a monitoring solution with ESP32 PLC.
To monitor the production process, sensors and PLCs were installed on three of the lines where data collection was required. These were lines that needed to be digitized as they were running at full capacity but lacked to complement this type of information, which was partially done by hand, with the consequent loss of competitiveness and the possibility of human error.
In order to monitor the quantities produced, weight sensors were installed on the production line, so that the total number of units and also the total weight of the packaged product are known.
The database processes this data to calculate the quantity of products packed in each batch.
To manage product batches, an identification system is used that assigns a unique batch number to each packaged product. This number is created from the marking system and sent to the PLC.
The batch is recorded in the PLCs for later use in the secondary packaging groupings and sent to the database.
To group the batches by case, a counting system is used that counts the number of products packed in each case and compares it to the required quantity per case.
If the required quantity is reached, a unique box number is assigned and recorded in the PLC and in the central database.
A barcode scanner connected to the PLC and the line is also used to read the barcodes of each grouping of products in boxes.
RESULT OF MONITORING SYSTEM
The proposed solution has allowed the company to correctly identify the products and their groupings, as well as to monitor and save the production process.
It was imperative for the end customer to be able to ensure the traceability
of the products and to do so automatically.
In addition to meeting their customer's needs the implemented system provides valuable information on:
The quantity produced in units
Total product weight
Product batches
Batch groupings per carton
Barcodes of each primary packaging
The groupings in secondary packaging
The company uses this information to optimize the production process, improve efficiency and ensure traceability and quality of the final product.
The production status information can be visualized in real time and at the same time sent to a central database where it can be worked with and the acquired data can be converted into relevant information for decision making.
Previously this information was not available in real time and human intervention to incorporate it into the ERP could lead to errors.
PostgreSQL has been selected because of the large amount of data that can be managed quickly, but other types of databases such as SQL or SQLite can also be used.
The control of the conveyor belts has been done by PWM and the use of encoders.
The company processes multiple products with various packaging formats and it is important to be able to have up-to-date information without having to wait for it to be entered into the system.
INSTALLATION SCHEME OF THE PACKAGING MONITORING SYSTEM
BENEFITS OF THE SOLUTION
Real-time monitoring
The system provides real-time information on the production process, allowing production managers to make immediate decisions.
Tracking and traceability
The system records and stores information on product batches and barcodes for each primary and secondary packaging, ensuring traceability.
Error reduction
Automation of the monitoring process reduces the possibility of human error and improves the accuracy of the data collected.
Improved efficiency
By having real-time information, the company can identify areas that need improvement and optimize the production process, which can lead to improved efficiency.
Increased product quality
The ability to monitor and track the process can improve the quality of the final product and reduce the risk of defective or contaminated products.
¿WHY INDUSTRIAL SHIELDS?
Industrial Shields won the project and beat its main competitors thanks to the following points: