Complete automation of a line with 9 conveyor belts.
Project name:
Croissant packaging line
Location:
Ilfov, Romania
Date:
May 23, 2024
Project Type:
Packaging
Intro:
We carried out a complex industrial automation project for a production line dedicated to the packaging and inspection of chocolate-filled croissants.
The system integrates 9 conveyor belts with distinct functions, controlled and synchronized via a PLC and HMI interface, ensuring a continuous and safe flow of products from packaging to final inspection.
General process overview:
- Belt 1 – Transports empty boxes from another room and accumulates them for the operators. It operates at two speeds (high/low), automatically switched based on load level, monitored via sensors integrated into the PLC logic.
- Belts 2–6 – Transport packaged croissants, already checked by the X-ray system for metal detection. Operators pick the products from these belts and place them in cardboard boxes.
- Belt 7 – Transports full boxes to the final inspection area.
- Belt 8 – Collects rejects from the process and automatically directs them to the waste area.
- Belt 9 – Auxiliary belt, optionally activated from the HMI when processing other product types (special croissants).
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Automation and control:
The project was fully executed by our team, covering all stages:
- Complete design of electrical and logic schematics;
- PLC and HMI programming;
- Wiring, connections, and control panel assembly;
- On-site testing, commissioning, and optimization.
The control logic was designed to optimize production flow, reduce downtime, and ensure the protection of equipment and operators. Sensor monitoring and automatic speed or routing commands allow for a stable, safe, and energy-efficient process.
HMI Interface and PLC Programming:
- The HMI enables fast and intuitive control of the entire production line, including:
- Real-time equipment and sensor status monitoring;
- Easy adjustment of conveyor speeds and operating modes;
- Activation of auxiliary functions and automated rejection;
- Quick response to alarms to avoid downtime.
The interface was designed so that the process can be managed clearly, visually, and completely safely, reducing the risk of errors and increasing the line’s efficiency
Results:
- Increased packaging efficiency and capacity;
- Elimination of blockages and unplanned stoppages;
- Improved traceability and control via HMI;
- Scalable automation, easily adaptable for new products.
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Strada Constantin Moise Nr.11