Automatic palletizing and labeling,
secured flow with carton-pallet matching.
In the project implemented at PMI's cigarette manufacturing plant in Torbali, Izmir, the automation and labeling processes in the palletizing area were renewed. SCADA and PLC infrastructure was updated to secure carton-pallet matching and automate production order management, with full SAP WMS integration.
Palletizing and shipment automation in the tobacco sector
In the project implemented at PMI's cigarette manufacturing plant in Torbali, Izmir, the automation and labeling processes in the palletizing area were renewed. Produced products are prepared on a carton and pallet basis and directed for shipment.
The project was carried out to automate this palletizing and labeling process, secure carton-pallet matching, and eliminate the risk of errors from manually running production orders and sorting processes.
Wrong labeling and manual sorting risks
Palletizing and labeling processes needed to be made more reliable, automatic, and traceable. There was a need to ensure correct printing of pallet labels, match cartons to the correct pallets, and eliminate the risk of errors from manually running production orders and sorting processes.
- 01Wrong Label PrintingManual selection for pallet label printing carried the risk of shipping incorrect customer or product labels.
- 02Incorrect Carton-Pallet MatchingManual placement of cartons on pallets led to the risk of wrong carton-pallet matching and shipment errors.
- 03Blacklisted ProductsThe lack of automatic blocking for products not permitted to pass created operational errors.
Renewed SCADA, pallet labeling, and blacklist management
The SCADA system in the palletizing area was renewed and the PLC structure managing the palletizing system was updated. Pallet labels were printed with label printers, carton labels were read to achieve carton-pallet matching. Production order start processes were organized and sorting lines were automatically planned. Additionally, a blacklist application was set up to block products not permitted to pass. The system was configured to work integrated with SAP WMS.
Production Order Start
A production order is started from the SCADA interface; sorting lines are automatically programmed per the assembly plan.
Pallet Label Printing
At the palletizing point, the label printer automatically prints the relevant pallet label.
Carton-Pallet Matching
Carton barcodes are read and matched with the relevant pallet; blacklist checks block any unauthorized products.
SAP WMS Transfer
Matching and labeling data is instantly transmitted to the SAP WMS system.
C# SCADA and PLC-based palletizing infrastructure
C# SCADA Application
SCADA managing pallet label printing, carton-pallet matching, production order management, and blacklist control.
PLC Palletizing System
PLC structure physically managing palletizing and sorting flow, operating integrated with SCADA.
Label Printers
Industrial thermal label printers automatically printing pallet labels.
Barcode Readers
Readers scanning carton barcodes to initiate the pallet matching and verification process.
SAP WMS Integration
The system operates integrated with SAP WMS; pallet-carton matching, production order, and sorting data are shared with SAP WMS, and palletizing and shipping processes are centrally managed.
Error-free palletizing and automatic shipment preparation
Secured Carton-Pallet Matching
The risk of wrong carton-pallet matching and erroneous shipments is zeroed out with automatic reading and matching.
Blacklist Control
Products not permitted to pass are automatically detected and blocked, increasing shipment accuracy.
Automatic Sorting Planning
Sorting lines are automatically programmed without manual intervention based on the production order.
Meet Our End-to-End Traceability Solution
OnSuite Trace allows you to manage all your production processes from a single platform. We provide end-to-end digital traceability for your business with the motto "Continuous Control, Zero Defects".
Related Projects
Türk Tuborg - Trasabilitate Butoaie cu OCR
The project implemented at Türk Tuborg's production facility in Izmir enables reliable identification of each keg through barcode and OCR technologies, ensuring accurate pallet association and pallet-level traceability.
Details
Nuh'un Ankara - Trasabilitate Cutie Palet Expediere
The project implemented at Nuh'un Ankara's production facility in Ankara provides carton and pallet-level traceability while enabling the monitoring of all product movements between the factory, external warehouses, and customers.
Details
Abalıoğlu Yağ - Trasabilitate Cutie Palet Lapte Praf
The project implemented at Abalıoğlu Yağ's milk powder production facility in Niğde provides carton and pallet-level traceability, enabling all product movements from production to shipment to be managed through a single platform.
DetailsWant to transform your production processes too?
Contact us to discuss how we can implement a similar solution for your business.
Get in Touch