Integrated Packaging Line Automation for Multi-Product Handling

🧱 Challenges

Haldiram’s faced several operational complexities due to the nature of multi-product packaging on a single production line. Key issues: 📦 Complex Product Packaging • Multiple SKUs running on the same line led to frequent changeovers, risking setup errors and inconsistencies. • Varying packaging requirements increased the chance of incorrect products entering production. 🔄 System Integration Gaps • Disconnected systems like SAP (inventory), barcode scanners, checkweighers, and inkjet printers operated in silos. • Lack of real-time data sharing caused delays, inaccuracies, and reporting lags. 🛠️ Quality Assurance • Manual quality checks led to inconsistent results in barcode printing and weight validation. • Ensuring compliance with standards and eliminating human error remained a challenge. ⚙️ Operational Inefficiencies • High operational costs due to manual interventions, downtime during changeovers, and data entry errors. • Need for an integrated, automated solution to streamline processes and reduce errors.

⚙️ Solution Overview

To address these challenges, a fully integrated Packaging Line Automation System was implemented, combining: • SAP ERP for real-time inventory data. • Barcode scanners with vision technology for accurate SKU identification. • Checkweighers for automated weight validation. • Markem-Imaje inkjet printers for direct barcode printing on cartons. • Centralized software to manage and monitor the entire system.

The system was designed with four sub-systems—Scanning Conveyor, Check Weighing Conveyor, Rejection Conveyor, and Printing Conveyor—working in harmony at 13–18 cartons per minute. Real-time data validation ensures only correctly packed and weighted cartons are printed and dispatched, while deviations are automatically rejected.

🔑 Key Benefits

✅ Live SKU Tracking prevents incorrect material usage. 🧾 Automated Barcode Printing & Validation reduces human error. ⚖️ Integrated Checkweighers ensure packaging compliance. 🔗 SAP ERP Connectivity for seamless inventory updates. 🚀 Increased Throughput & Efficiency via modular conveyor systems. 📉 Reduced Downtime & Operational Costs with faster product changeovers. 🛡️ Regulatory Compliance and enhanced traceability across the line.

🌟 Conclusion