Composite Pack End of Line Palletising
Twenty five conveyors, servo driven row forming, a palletising robot, and three safety zones sharing one line. Every device on it needed power, network, and safety wiring that would stand up to continuous production.
Client
Cantech Engineering / Zipform Packaging
Industry
Food & Beverage
Location
Dandenong, Victoria
Duration
Jan 2023 to Dec 2023
Scope of Works
This end of line system handles rigid composite packs from upstream production through to a wrapped, strapped pallet. It takes in 25 conveyors, communicates with wrapper and strapper systems, and integrates with the equipment feeding it, with sensor blocks positioned around the line to keep track of product.
The hardest part was presenting product to the robot. The solution was a control strategy using servo drives and pneumatic stoppers to form rows before the robot picks them, which meant precise wiring of drives, stoppers, and position feedback across a long line footprint.
Three separate safety zones were created, each rated PLd SIL2, so an incident in one part of the line does not shut down the whole system.
The Electrical Delivery
Alongside Scope Automation
Scope Automation delivered the Siemens S7-1500F control system, including the row forming strategy that presents product to the robot. Running ProfiSafe over Profinet meant safety and control shared the same network, which cut the amount of hard wiring needed and made the three safety zones far cleaner to build and prove.
Key Technologies
From the Job
One Line, Three Zones, No Full Stops
The system runs composite packs from upstream production through row forming, robotic palletising, wrapping, and strapping as one coordinated line.
Splitting it into three PLd SIL2 safety zones means an access gate or e-stop in one area drops only that zone. The rest of the line keeps running, which over a year of production is a substantial amount of recovered output.
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