July 18, 2022
A Polish manufacturer of plastic bags for food packaging recently expanded its automated facility and installed additional machinery. She took the opportunity to install a centralized control and management system for all of her workshop machines.
The vacuum and high barrier plastic bags produced at the factory are used in the food and beverage industry. Several heat sealing machines and conveyor systems were in use at the plant before the expansion. Traditionally, there was no way to collect and analyze machine production data from a single location.
A new custom solution should have the ability to collect and aggregate data from all machines – including new ones – and generate corresponding reports and graphs.
Since the manufacturer was already using Delta automation hardware, Delta’s DIAView SCADA solution was an obvious choice to implement centralized control and visualization. Delta’s trusted partner in Poland, Induprogress, was able to deploy a combination of DIAView SCADA and SQLServer to collect production logs and statistics and aggregate this data into a central database.
The system implemented for the packaging plant allows users to choose individual machines and generate reports covering the selected period without an operator going to the physical machine and using the HMI. Reports can be generated from the plant control room or anywhere else in the plant. Each machine’s HMI functionality is now also available from DIAView, allowing remote control and operation. The DIAView system accesses production information hosted in the SQL database to generate graphs and reports.
The Delta solution is built around an autonomous instance of DIAView, also available in client/server version and in browser version. Delta’s additional equipment in the plastic bag factory includes an Ethernet switch to enable communication between DIAView and the machines.
Additionally, servo drives have been installed to enable bag making and bag filling processes. The VFDE series Delta motor drives come into play for the sealing tasks.
The manufacturer now uses the new DIAView SCADA system to control individual machines and monitor the production line. Trend charts are available and traders can check anomalies and generate reports. Some of the available metrics include total machine hours, average production speed, and machine efficiency. Users can be assigned different levels of permissions and an operator log stores the history of each user’s actions, allowing operator performance to be monitored. The software interface has also been localized into Polish to make it even easier to use for local workers.
In case the plastics manufacturer installs more machines in the future, it plans to acquire additional DIAView licenses and integrate them into the existing system.