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Connecting PLCs for high-speed packaging quality

Stone Technologies creates an effective automated defect rejection process requiring deterministic communication between controllers on separate parts of a high-speed packaging line.

Bird's-eye view of the packaging line with a turner/diverter/rejector table.
Bird's-eye view of the packaging line with a turner/diverter/rejector table.

Packaging lines are well-known examples of multi-PLC operations. There are PLCs on the conveyor lines, which may or may not be provided by the conveyor supplier, and there are packaging machine PLCs typically provided by the OEM.

This mix of controllers can produce some challenging control issues if you’re looking to connect controller communications in overlapping zones of control on a packaging line. And that’s exactly what a Fortune 500 international producer and marketer of beer, wine, and spiritsfaced when it added a new multipacker to an existing can line used for new package types.

At the Siemens Automation Summit 2019, Fred Husman, senior project manager at system integration firm Stone Technologies, described how they handled this issue to facilitate an automated rejection of packages with defects. The multipacker in this application was added to an existing packaging line to handle a new type of sleek can, creating a system with five PLCs—one for the multipacker, two for the conveyors, one for the turner/diverter/rejector (TDR) table, and one for the tray packer. “In this line there were older Siemens S7 300 series PLCs, newer S7 1200 PLCs, and a Siemens Simotion controller,” said Husman.

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