Synchronized packaging operations with MES connectivity
A food production facility specializing in sauce manufacturing required the integration of a complete packaging line, from filler to palletizer, into a unified automation environment. The objective was to coordinate all OEM machines, quality control devices, and conveyors while enabling connectivity with the plant’s MES system.
Contec implemented an automation solution that centralizes line control, synchronizes machine operations, and ensures seamless communication between equipment, quality devices, and higher-level systems. The result is a connected packaging line with improved efficiency, traceability, and production visibility.
Project Overview:
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Integration of a complete packing line from filler to palletizer
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Centralized control using a line master PLC
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Integration of checkweigher, metal detector, and vision systems
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MES connectivity for production orders and traceability
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Standardized HMI for full visibility of line status and alarms
The challenge
Coordinating multiple systems within a single packaging line
Modern packaging lines often include equipment from multiple OEM suppliers, each with its own control system and communication protocols. Without proper integration, this can lead to inconsistent machine behavior, inefficient line coordination, and limited operational visibility.
The challenge was to coordinate all machines, from filling and conveying to inspection and palletizing, within a single control system.
In addition, quality devices needed to be integrated to ensure automatic rejection of defective products and reliable data capture for traceability. The line also had to connect to the plant’s MES/ MOM system for order execution and performance monitoring.
Our approach
Implementing centralized line control and system connectivity
Contec implemented a centralized control architecture based on a Rockwell line master PLC, responsible for coordinating all machines and quality systems across the packaging line. Electrical engineering covered conveyors, auxiliary systems, and the integration of quality devices, ensuring a cohesive setup. The PLC programming included key functionalities such as sequential start/stop, run-empty procedures, and changeover control to maintain smooth and consistent line operation.
Operator interfaces were developed in FactoryTalk View, providing real-time visibility into machine status, alarms, and interlocks, enabling operators to quickly respond to operational events. OEM integration involved aligning communication interfaces and data mapping, allowing real-time exchange of machine states, commands, and production data.
Quality systems, including checkweighers, metal detectors, and vision systems, were integrated to manage rejection logic and support traceability. In addition, a MES connectivity layer was implemented to enable production order execution, recipe and lot management, and the collection of operational data for performance monitoring.
