Intelligent Automation of Sack Transport
The challenge
The sustained increase in the mill's production capacity created the need to expand the volume handled in the packaging room. From an initial manual line, a second line with an automated bagging machine was added. Until then, both operated alternately, but current demand requires them to operate simultaneously to achieve production volumes.
The two lines converge on a single output conveyor, which raised a major challenge: coordinating the advance of the bags to avoid collisions at the junction point and ensuring the synchronization of all conveyor belts.
The previous system presented risks of interference and operational limitations, affecting productivity and safety. It was necessary to implement a modern and reliable solution to serve this demand.
The solution
Intelligent control system.
An intelligent control system was designed and implemented for conveyor lines and sugar packaging. It included a motor control panel consisting of drives connected via Ethernet/IP.
It integrated:
- Intelligent CCM composed of frequency converters (Allen-Bradley PowerFlex 525, 5 HP).
- Control panel with 12" touchscreen HMI, emergency stops, and line indicator lights.
- Photoelectric sensors for real-time bag detection.
- Integration with the bagging machine, with automatic interlocks.
- Optimized control logic, maximizing the number of bags transported per unit of time.
- Compliance with NOM-001-SEDE-2012 in the electrical installation.
The benefits
Modern and reliable solution, packaging system that responds to packaging demand and offers potential for future growth.
- Increased productivity: precise synchronization between lines, reducing downtime.
- Flexible operation: selection of packaging formats (sealed or stitched bags) and manual/automatic modes.
- Enhanced safety: emergency stops and motor fault detection.
- Reduced bottlenecks and increased continuity.
- Energy and maintenance efficiency, thanks to state-of-the-art frequency converters.
Impact on the plant
Increased efficiency, safety, and productivity.
The customer obtained a modern, secure, and scalable system that allows both bagging lines to operate simultaneously, synchronized and without interference, achieving maximum efficiency in bag transport and responding to growing production demand.
2022 Sugar conveyor belt control