AUTOMATING
PACKING
SYSTEM
OVERVIEW
01 02 03
Our Team Introduction Current System
04 05 06
Proposed System Deployment Plan KPI Strategy
What is Industrial Automation
Use of control systems such as computers,
programmable logic controllers (PLCs), and
robotics to handle industrial processes with
minimal human intervention. The goal of
automation is to increase efficiency, reliability,
and production speed while reducing human
error and operational costs
Automation and the Food Industry
• The food processing industry has greatly benefited from automation,
particularly in ingredient handling, mixing, and packaging.
• The food industry relies heavily on maintaining strict hygiene standards,
efficient production, and quality control.
• So, Automation allows food producers to,
Enhance Food Safety
Increase Production Capacity
Real-Time Monitoring and Adjustments
❑Reduces human errors,
❑ensures consistent product quality, and meets the increasing global
demand for food.
❑ In food processing plants, automation improves hygiene and safety by
reducing manual handling of materials, which is critical in industries that
require high levels of sanitation.
For example, the introduction of PLCs, robotics, and sensors
has allowed real-time monitoring and adjustments to food production
processes, ensuring uniformity and high production standards
CLIENT - INTRODUCTION
Silvermill Group is a prominent name in Sri
Lanka's coconut industry, with a rich history
that spans over 90 years.
• Founded in 1920, the company has
established itself as a leading manufacturer
and exporter of a wide array of coconut-
based products.
• Product range –
-coconut oil, desiccated coconut,
coconut milk, coconut cream, and a variety of
other coconut products.
Connecting Silvermill's Products to an Automation System
• Precision, efficiency, and consistent quality.
Manual processes
• Time-consuming
• Prone to inconsistencies
• It can affect product quality
and lead to higher labor
costs.
By automating these processes, Silvermill can:
• Increase Efficiency
• Improve product quality
• Ensure Consistency and reduce human errors
• Reduce Labor Costs
THE CURRENT SYSTEM OF THE COMPANY
• Process involves sorting, weighing, and packing coconut
products.
• Workers collect coconut chips from the dryer into buckets and
manually transport them to the sorting area.
• Coconut Chips are spread on a mesh sorting table.
• Larger Chips remain on the top & smaller chips fall through the
holes
• Workers manually weigh the coconut chips using a digital scale.
• After weighing, they manually package and seal the products.
CHALLENGES IN THE SYSTEM
01 Labor-Intensive
➢Heavy reliance on manual tasks, increasing worker
strain and fatigue
.
02 Slow Process
➢delays and slower production cycles.
Quality Inconsistencies
03
➢ Variations in product weight and packaging due to
manual handling.
04 Error-Prone
➢Increased risk of mistakes from repetitive manual
tasks.
CURRENT PRODUCTION COST AND RATES
• Production Rate: 70 packets/ hr
• Weight Of one product - 40g and 500g (secondary product)
• Labors are working on a Shift basis.
➢ There are two shifts day and night
➢A one shift is include 12hrs = 8 hrs (standard) + 4 hrs (Over
Time)
Labor Cost:
Standard Rate = Rs 202.41 per hour
Over Time = Rs 303.60 per hour
OPERATIONAL GOALS
• Speed up the sorting, weighing, and
Increase Efficiency packaging processes to boost
• Minimize the need for manual production output.
labour, freeing up workers for
Reduce Labor
more skilled tasks. Dependency
Enhance Product • Ensure consistent weighing,
sorting, and packaging to
maintain high product
Quality standards.
• Cut down labour costs and
reduce waste from manual Lower Operational
errors.
Costs
• Reduce the risk of
Improve Safety worker injuries.
Proposed Automated Packing System Overview
• Key stages:
• Discharge belt
• Vibrating Shifter
• Packaging
• Sealing.
• Replaces manual labor with
automated processes.
• Aims:
• Efficiency
• Accuracy
• reduced Labor cost
SCADA for Real-Time Monitoring
• SCADA gathers data
from sensors and
actuators.
• Monitors production
rate, system status,
and faults.
• Ensures real-time data
tracking and
diagnostics.
Operator Control via HMI
• User-friendly graphical
interface for control.
• Control conveyor speed,
packaging weights.
• Displays live data and
alarms for quick
response..
Technology Choices
Capacitive proximity sensors for detecting packets.
Load cells ensure precise product weights.
Food-safe PU conveyor belt for transporting
unpackaged foodstuffs
Technology Choices
Siemens S7-1200 PLC for reliable automation.
SIMATIC HMI for user control.
DEPLOYMENT SCHEDULE
❖ Main Components:
▪ Siemens S7-1200 CPU (Main PLC Unit)
▪ Siemens SIMATIC HMI TP1200 (Real-time Monitoring)
▪ Digital I/O Modules (Expansion)
▪ Power Supply, Sensors, Load Cells, Conveyors, and
Miscellaneous
❖ Total Cost = Implementation Cost + Component Cost
= Rs 8,561,154 + Rs 4,188,846
= Rs 12,750,000. 00
HARDWARE INTALLATION PROCESS
❖PLC (Siemens S7-1200):
▪ Mounted on a DIN rail in the control cabinet.
▪ Powered by a 24V DC supply.
▪ Sensors and actuators connected to input/output terminals.
❖HMI (SIMATIC HMI TP1200):
▪ Installed at the operator’s panel.
▪ Connected to PLC via Ethernet for real-time monitoring and
control.
❖Wiring and Network:
▪ Ethernet cables used for communication between devices.
▪ Low-voltage wiring organized for safe connections.
MECHANICAL INSTALLION
❖Conveyors and Shifter:
▪ Installation of 6-meter Conveyor Belts
▪ Vibrating Shifter for Sorting
▪ Sensors along the Conveyor Line
for Automation
❖Final Integration:
▪ Power and Control via PLC Vibration
▪ Testing and Alignment
PROGRAMMING AND TESTING
❖Programming:
▪ Siemens TIA Portal for Logic Configuration
▪ HMI Screens for Real-Time Monitoring and Alarms
▪ Communication Protocols (PROFINET/Modbus TCP/IP)
❖Testing Phases:
▪ Dry Runs without Materials
▪ System Integration Tests for PLC-HMI Communication
▪ Pilot Tests with Real Products
RISK MANAGEMENT
❖Key Risks:
▪ Calibration Failure (Load Cells, Sensors)
▪ Programming Bugs (Testing in Virtual Environment)
▪ Safety Risks (Emergency Stops, Safety Audits)
▪ Testing Shortfalls (Functional, Integration, Stress Tests)
❖ Mitigation Plans:
▪ Regular checks, Safety Audits, Version Control
KPI Evaluation Plan
A KPI Evaluation Plan is structured to measure the
effectiveness and success of the project using Key
Performance Indicators (KPIs).
• Production Output: Measures efficiency by tracking the
quantity produced over time.
• Return on Investment (ROI): Evaluates financial
benefits from automation investment.
Production Output
The production output KPI tracks the amount of
product produced over a specific time period,
helping to assess whether the automation system
meets its targets.
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒
Achivement = × 100%
𝑇𝑎𝑟𝑔𝑒𝑡 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒
Target Yields
Main Product - 86%
By Product - 12%
Waste - 2%
Return on Investment
Compares costs of automation against savings
from increased output.
𝑇𝑜𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
Recovery time =
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡 𝑝𝑒𝑟 𝑀𝑜𝑛𝑡ℎ
12,750,000
=
1,187,200
= 10.74
= 11 months
•Total Investment: Rs 12,750,000.00
•Monthly Net Profit: Rs 1,187,200.00
•Recovery time: 11 months
Other KPIs
•Operational Efficiency: Measures system's reliability and downtime.
•Product Quality: Tracks consistency and precision in packaging.
•Cost Savings: Reduction in labor and material wastage.
THANK YOU
