Automation of a packaging line and warehouse order management
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Project name:
Packaging line and warehouse order management
Location:
Timisoara, Romania
Date:
February 19, 2020
Project Type:
Packaging
Intro:
We have developed a complex logistics automation project for a product warehouse, aimed at optimizing the order preparation, packaging, and shipping process. The system was designed to ensure a continuous and controlled flow between the product preparation area and the final packaging area, reducing downtime and the risk of human error.
General Description:
The process starts in the preparation area, where operators select orders, print the corresponding labels, and collect the products in plastic bins.
After completing multiple orders, these bins are placed on a 15-meter conveyor belt, which transfers them to the final packaging and labeling area.
On both sides of the belt, operator workstations are arranged, each equipped with a barcode scanner, local HMI, and start/control button.
Operators lift the bins from the conveyor, scan the box barcode, check the products, and package them according to the order.
Depending on the client or destination, the system automatically selects the courier company and generates the corresponding AWB.
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Automation and smart flow:
The line operates in groups of four workstations, logically synchronized:
- The next bins are released only after all four operators finish and press Start.
- This keeps all stations synchronized and eliminates bottlenecks.
- Each station has a mushroom-type emergency stop for maximum safety.
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After emptying, bins are automatically transported via a transversal conveyor to the collection area for reuse.
Control and Visualization:
The entire process is managed by an industrial PLC, with intuitive HMIs that allow:
- real-time monitoring of the flow,
- adjustment of parameters according to client requirements,
- display of alerts, sensor statuses, and safety signals.
All safety systems, sensors, scanning, cabling, interlocks, and signaling were fully implemented by our team, with a focus on safety, reliability, and easy maintenance.
For the mechanical part — conveyors, chains, pneumatics, and lifts — we collaborated with a specialized conveyor systems partner, ensuring perfect integration between mechanics and automation.
Benefits:
- Complete automation of the packaging logistics process;
- Intelligent synchronization between workstations;
- Full traceability through barcode scanning;
- Increased productivity and reduced waiting times;
- Safe, intuitive, and easily expandable system.
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Phone Numbers
Location
Strada Constantin Moise Nr.11