The challenge
The client required a fully automated end-of-line packaging solution capable of closing, gluing and labelling boxes at throughput, with reliable product validation throughout. The system needed to integrate with multiple third-party machines — a Nordson melter/gluer and an ICE Vulcan labeller, each with their own proprietary control interfaces.
Accurate traceability throughout the process was critical. An LBN barcode on the side of each incoming box was read to identify the product, the correct label was then applied by the Clearmark ICE Vulcan labeller, and a Cognex camera validated the applied label before the box was released downstream. Operators also needed a single, remotely accessible interface to monitor and control the entire line — including the third-party machines — without switching between systems.
The solution
Led controls and HMI delivery for the full line, built on Beckhoff TwinCAT 3 with a web-based TwinCAT HMI accessible remotely, giving operators a single point of control over the PLC, the Nordson gluer, and the Clearmark ICE Vulcan labeller from any networked device on site.
- Nordson gluer integration, parameter control, fault monitoring and status feedback within the HMI
- Clearmark ICE Vulcan labeller integration via tcp/ip — label data, print triggers and validation feedback
- Cognex vision integration for label presence and position validation post-application
- WMS integration for real-time label data and order-driven product routing
- PILZ safety hardware and TwinSAFE control for machine guarding, emergency stop and safe state control
The web HMI was designed to show all aspects of the line in one place, live machine state, active faults across all three systems, production counters, and direct control of gluer and labeller parameters without needing to access their local panels. Remote access allowed off-site diagnostics and fault resolution without requiring an on-site visit.
Commissioning & delivery
Commissioning involved co-ordinating integration across three separate vendor systems simultaneously, aligning comms protocols, testing handshakes between the PLC, gluer and labeller, and validating Cognex pass/fail logic against live production samples. FAT and SAT were conducted on site, with structured test plans covering all machine states, fault conditions and safety functions.
The result
Delivered a fully automated system handling box closing, gluing, labelling and validation in a single continuous process. The web HMI consolidated control of three previously separate systems into one interface, reducing operator overhead and enabling remote fault resolution. Cognex validation eliminated mislabelled product reaching despatch, and WMS integration ensured accurate label data throughout.