Smart integration of robotics and vision systems into an existing PackML-controlled environment
To increase production speed and improve quality control, a global consumer goods manufacturer set out to enhance an existing packaging line by integrating a new robot and vision system. The line was already controlled via PackML-based packaging platform, requiring any new addition to seamlessly fit into the existing architecture while maintaining full operational control and safety compliance.
Contec delivered a PackML-aligned integration that enabled the robot and camera system to operate as an integral part of the line, fully visible, controllable, and optimized for performance.
Project Highlights:
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Integration of robot and vision system into existing packaging line
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Development of PackML-compliant PLC add-on
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Full alignment with PackML-based line control system
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Centralized monitoring and control via HMI
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Enhanced quality inspection through camera integration
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Rapid implementation within tight project timeline
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Improved line performance and reduced manual intervention
The challenge
Enhancing line performance without disrupting an established control system
The objective was to improve both speed and quality of a running packaging line by introducing robotic automation and automated inspection capabilities.
However, the existing system, controlled via PackML-based packaging platform, required that any new equipment be fully integrated into its architecture, both functionally and visually from an operator perspective. The robot and camera needed to behave as native elements of the line, not as isolated systems.
Additionally, the project had to be delivered within a tight timeframe, with limited room for extended testing or operational disruption. Ensuring compliance with PackML standards and maintaining full machine safety added further complexity.
Our approach
Seamless integration through PackML standardization and smart system design
Contec approached the integration by extending the existing PLC architecture with a dedicated PackML-compliant add-on, specifically designed to incorporate the robot and vision system into the PackML-based environment.
The solution ensured that machine states, commands, and feedback were fully aligned with PackML standards, allowing the new equipment to operate consistently within the broader line logic.
The robot and camera were integrated into the HMI interface, enabling operators to monitor and control the entire line, including the new components, from a single point of interaction.
Special attention was given to safety integration, ensuring that the robotic system met all required standards while remaining synchronized with the rest of the line.
Despite the tight timeline, the system was fully tested and commissioned efficiently, ensuring readiness for production without delays.
