Ensuring packaging accuracy across multiple production lines
A global ice cream manufacturer required a solution to prevent cross-packing errors between several production lines, reducing the risk of product recalls and production losses. Incorrect packaging represents a major risk in food manufacturing, potentially leading to product recalls, production losses, and negative consumer impact.
Contec implemented a standardized quality control system that combines barcode verification, machine interlocks, and centralized control logic to ensure only correctly packaged products continue through production. The solution improves reliability while minimizing disruptions caused by packaging errors.
Project Snapshot:
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Site-wide rollout of a cross-packing prevention system
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Integration of barcode verification for packaging validation
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Machine interlocks to stop or divert incorrect products
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Standardized architecture for efficient deployment across lines
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Improved product quality and operational reliability
The challenge
Preventing packaging errors across multiple production lines
In facilities producing multiple product variants, packaging errors can lead to quality issues, regulatory risks, and costly recalls.
The factory required a new quality control system capable of detecting incorrect packaging in real time and preventing affected products from continuing through the production process.
At the same time, the solution needed to integrate with existing OEM production machines while maintaining production efficiency. The system also needed to be scalable and standardized to support deployment across multiple lines with minimal disruption.
Our approach
Implementing real-time verification and control across production lines
Contec implemented a standardized automation solution based on a Rockwell 5069-L380 PLC, developed in Studio 5000, with operator interfaces in FactoryTalk View ME.
Dedicated control cabinets were designed and installed on each production line to host the verification and control components.
The system integrates Cognex DataMan 2D barcode scanners for real-time packaging validation, directly connected to the PLC.
Machine interlocks were implemented to interface with OEM equipment, automatically stopping or diverting products when incorrect packaging is detected, preventing faults from propagating further along the line.
The project also included control panel manufacturing, construction documentation, and on-site commissioning. The standardized architecture enables efficient rollout and supports future expansion.
