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Updating Label Detection System for Automated Beverage Production
Quality assurance issues were plaguing a bottling facility, as their current label detection system wasn’t catching missing or misapplied labels. E Tech Group was able to integrate three systems into one, allowing for more accurate detection and less missed bottles.
The Project: Remedy the Output Bottleneck Caused by Missed Bottles
An internationally-distributed beverage production company wanted to upgrade their facility’s inspection station to check for missing body, back and neck labels on their bottles before shipping. Quality control was a growing concern and ensuring consistency in each shipment was a must.
Their current label inspecting system wasn’t meeting expectations; imperfectly applied or missing labels were making their way through. This cost the client in time, waste and slowed-output, not to mention threatened consistency assurance in their packaging.
The Challenge: Integrating Three Systems into One on a Tight Timeline
Our team started with a site visit to walk through the customer’s existing control system solution, helping them better understand current challenges and working to define the desired end result and deliverables.
This exploratory review would uncover that we would not be implementing a single system, as was originally outlined in the proposal, but the integration of a new system while simultaneously supplementing the existing system and upgrading the PLC to tie everything together.
The rigid production schedule standard in food and beverage automation would only allow for two days of downtime, each only 12 hours. This required all panels and hardware to be prefabricated before installation and perfect execution on a very truncated timetable.
The numerous moving pieces would dictate the need for strict project management, frequent and open communication, and detailed documentation for any changes in schedule or equipment that might happen throughout the project. Without effective coordination between our automation team and the client, implementation of the new control systems could end up problematic.
The Solution: Build a Robust, Integrated Label Detection System
Coordination between teams translated to coordination between automation products as we pivoted from the original plan of single-system implementation. Instead, we brought together the existing Allen Bradley PLC (existing main panel), repurposed the Teledyne Taptone system that wasn’t providing the results they would like, and integrated the new Keyence label detection system to create one cohesive solution was a large undertaking.
Once the decision was made to implement a Keyence label detection system, the E Tech Group team designed, built and oversaw the installation of the two control system panels that would house the Keyence systems. Both panels were installed close to the reject area after the automated labelers.
Our team actively troubleshot the installation as they went because nothing like this had ever been attempted with the Teledyne product, and between the client and component manufacturers, there were differing opinions on how this should be set up.
E Tech’s automation specialists were able to get the cameras working quickly, but getting them to interface with the Teledyne system wasn’t as easy. A missing trigger signal that would initiate a bottle with a bad label to be diverted was the culprit. Our team moved and reordered some components while repurposing Teledyne photo eyes that weren’t being used, tying them back into the Teledyne system at the same point the Keyence system was being tied in, providing the supplementary signal needed to get the desired results.
Once the system was functioning properly, it was a matter of fine tuning. Our team would be on site, making sure any adjustments were made during planned downtime to not disrupt the client’s production schedule.
Understanding the Scope of Work on this Process Integration Project
The nature of this project required multiple efforts:
ELECTRICAL DESIGN
One generic drawing package was created that detailed the vision systems. An Engineering Information (EI) document package was provided, sufficient to allow for review of the proposed updates, installation by a qualified electrical contractor, and continued maintenance and support, by plant personnel, of the updated equipment, hardware, electrical panels, or controls.
PLC ENGINEERING
E Tech Group integrated the Taptone divert into the Keyence solution and the available PLC control system. The installation of the specified Keyence cameras and configuration was performed and tested. HMI screens were housed in one of the two panels that were supplied. This was the primary access point for the reject solution.
INTERNAL READINESS TESTING
One day for virtual readiness testing was included. A full test of the PLC and HMI was completed. Client and supplier representative(s) thoroughly reviewed the design, programming and commissioning schedule for the system being considered. A checklist was developed and used to identify the key aspects for each system that had been determined to be critical to the success of the installation and assessed the overall readiness. For programming updates, where possible, basic simulation was provided to show that the functionality of the updated system was unchanged.
ON SITE SAT
During commissioning, E Tech Group assisted in on site testing to prove the functionality of the reject system. The testing protocol matched the testing effort from the internal readiness testing. All test scenarios were communicated by Boston Beer prior to start of development. This testing was expected to be performed within one single downtime window.
ELECTRICAL INSTALLATION
Electrical installation will be provided by a third party. The internal controller of the Taptone system and Keyence system controller will get tied back into the pre-existing PLC. Wiring for IO and power is included.
ENGINEERING SUPPORT
One engineer was on site for installation and commissioning, which took one day for setup and commissioning took multiple part-days over the span of a week during planned downtime.
Infrastructure/communication checks (PLC, HMI)
Checking of all equipment IO (equipment level check only)
Parameter/timing adjustments
Operational checks of all system functions
Keyence configurations
Verify any old programs for each updated system are properly archived per site standards
The Results: Adaptation and Communication Made for Smooth Execution
Our team quickly adapted to the change in project parameters and developed, tested and implemented a prototype solution utilizing the selected technology.
Originally planning to implement and test over two twelve-hour days, the team once again pivoted, this time to accommodate the facility’s bottling schedule. Our control system integrators were able to complete the implementation over several days while stopping the line for only brief periods.
The onsite team ensured proper operation while the line was running, confirming the Keyence cameras rendered the correct decision and then had the reject signal sent to the Taptone system, verifying both systems were working properly together.
Through open and clear communication, changes in equipment and time frame were received well by the client and the overall project was a good experience for all involved. The relationship between E Tech Group and the client was strengthened, providing future opportunities to work together.
E Tech Group is a leading control system integrator serving clients across North America with customized automation systems that optimize the vital processes of their facility. Our engineers utilize their expertise, cutting-edge automation products, and a client-centered approach to help them optimize their operations now and in the future.
E Tech Group, a control system integrator that delivers turnkey automation solutions, and Apera AI, a company that offers AI vision guidance, partnered together to produce a webinar covering the capabilities of robotic integration with 4D vision technology, which you can watch below. AI & Vision-Guided Robotics: Talking Points What if we told you that vision-guided robotics powered by AI could do all of this? Identify objects in bins and give a robot picking instructions in only 0.3 seconds. Operate in changing light conditions with no special lighting or sensors. Remove the custom programming that makes projects expensive. Traditional vision systems required a lot of expertise to train and implement, and were not very resilient to lighting changes. The new system from Apera AI is self-programming and can handle variations in lighting conditions. Some key points from the webinar: The system uses two camera sets mounted overhead to look at a bin of parts. It can learn the entire process, including the different parts and the end-of-arm tooling, by itself. It is very fast and can be used in a variety of applications, including process or discrete applications. E Tech Group can also help with the digital modeling of the solution to test it before it’s implemented. Check out the video below to view a recording of the webinar, which was originally presented on May 9, 2023. We hope you’ll gain some new ideas about making your facilities more productive!
Not so long ago, the food and beverage manufacturing industry was among the slowest industry verticals to adopt new production technologies. But now, with the industry growing as aggressively as ever and faced with rising demand, the industry is increasingly relying on automation to keep the shelves stocked. Along with this increasing reliance, the industry has seen certain trends emerge: as to how food and beverage manufacturing is choosing to implement automation in their facilities, what’s driving those trends, and the challenges they face in augmenting the applications of automation in food production. What Are the Major Trends in Food & Beverage Automation? The most notable automation trends among food and beverage producers are: Digital transformation — This transformation must be planned from the top down, making sure to account for all moving parts and taking into consideration not only the transformation itself, but the operational team that will be responsible for daily monitoring and interpretation of data used to optimize the facility. Robotics — A robotic system can run as an island of automation, however its real power is delivered when it is integrated into your overall efficiency process. The robot cell design, end of arm tooling development, robot selection and integration of the design into the rest of your production or packaging line is what unlocks the powerful features of robotics. Artificial intelligence (AI) — This technology tends to play well when implemented in applications where a specific volume of product is meant to fill a container, like 16 oz. of ice cream to fill a pint. AI can help ensure the correct and exact volume is distributed into each pint, each time. It also provides the information necessary to diagnose inefficiencies in machinery that may be impacting production and help plant managers remain proactive around planned downtime, routine maintenance or … Continued
Integrating additional cooling towers in milk production can support a plant’s processing capacity and quality control. These results were desired by a leading American dairy producer who faced challenges with their milk production process. The dairy producer wanted to integrate two additional cooling towers with their existing system to improve production efficiency and support the increased demand for their milk products. The company engaged E Tech Group for this project as the system integrator developed their existing system and had the integration expertise to successfully deploy this project on-time and within budget.
Solution
The project required comprehensive control engineering support. This included system design and development, input/output validation, system functionality testing, and custom control panel design and fabrication based on the customer’s requirements. PLC, HMI, and SCADA programing were also needed to control and monitor the new equipment as well as balance the water flow between the customer’s cooling towers. E Tech Group engaged the engineering team to create the best controls strategy for the customer.
First, the project team verified the project scope with the customer and collaborated on proactive solutions to potential installation and integration challenges. Next, the project team developed the control system design including Rockwell Automation CompactLogix PLCs and PanelView Plus HMI, and Inductive Automation Ignition SCADA programing. New IFM I/O Link modules, PowerFlex drives and Soft Starters were also integrated to monitor new instruments and control new motors for pumps and fans added to the system. The project team integrated these components with the customer’s custom UL 508A control panel build, keeping safety, functionality, and durability of the design top-of-mind.
Results
The panel construction was executed in eight weeks and site commissioning was completed in three days including a few days planned for fine tuning. The integration and installation of additional cooling towers helped increase the customer’s milk processing capacity, supporting greater production efficiency and quality control. By investing in modern technology and upgrading their infrastructure, the plant was able to meet the growing and quality demand for their milk products and support its competitive edge in the market.
