Overview
Installation and integration of an automated vision and barcode verification system on a Tetra Pak packaging line at Tongala Nutrition, designed to eliminate manual setup and reduce operator error across multiple packaging stages.
The Problem
The production line relied on manual selection of barcode configurations, creating several issues:
- Risk of incorrect labels being applied (film, shrink packs, shippers)
- Operator error during changeovers
- No automated validation across all packaging stages
- Existing scanners operated independently without cross-checking
Additionally, there was no verification system for 6-pack shrink labels, leaving a gap in quality control.
What Was Implemented
A complete vision system upgrade and automation sequence was developed to streamline and safeguard the process:
- Installed and integrated a new barcode scanner for shrink-pack (6pk) labels
- Developed a centralised product database linking:
- Tetra film barcodes
- Shrink pack barcodes
- Shipper barcodes
- Implemented an auto-configuration sequence:
- System automatically selects correct barcode set based on product name and line configuration
- Eliminates need for operator input after initial setup
- Enabled cross-referencing between all barcode points across the line
- Configured system to:
- Stop the line and alert operators if incorrect materials are detected
Outcome
- Significant reduction in operator error during production and changeovers
- Improved quality control across all packaging stages
- Increased line reliability and consistency
- Reduced setup time and simplified operator workflow
- Full traceability and validation of correct materials in use
Project Delivery
Commissioning was carried out on a live production line, with works planned and executed to minimise disruption during operation and shift coverage.
Key Capabilities Demonstrated
- Industrial automation & system integration
- Vision systems & barcode verification
- Database-driven control logic
- PLC / line configuration integration
Working within live production environments