Cosmetics Filling & Packaging Upgrade
Design, assembly, and field wiring of 12 modular MCC and PLC control panels fully compliant with international IEC 61439 standards.
🎯 Challenge / Goal
Low-channel volumetric fillers capped throughput. 50+ SKU format changes exceeded 2 hours each. Spare parts obsolescence extended downtime. Manual case packing and shrink wrapping created high labor costs.
⚙️ Solution Applied
Replaced legacy Allen-Bradley controller with ControlLogix L81E and servo-driven filling valves. KUKA KR AGILUS robot cell builds case patterns dynamically from product dimensions. Integrated BMS RP120 shrink wrapper. Recipes stored in FactoryTalk SCADA and recalled in one click. Markem-Imaje laser coders print serialization and date codes inline.
📈 Results
- ✓Line speed: 80 → 160 units/minute (+100%)
- ✓Format changeover: 120 min → 8 min
- ✓Giveaway / overfill loss: 4.7% → 1.3%
- ✓Annual net savings: $175,000
- ✓50+ SKUs all handled on single line
🔧 Technologies Used
Allen-Bradley ControlLogix L81EKUKA KR 6 R900-2 (AGILUS)B+R X20 Remote IOLenze i950 Servo DrivesFactoryTalk View SE SCADAEthernet/IP Network Architecture
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