Secondary Packaging Automation for Tea Production

A leading European tea producer required an automated secondary packaging solution to reduce reliance on manual labour while increasing production throughput. The project also aimed to improve packaging quality and optimize material consumption. The production facility needed an integrated system capable of maintaining high operating speeds with consistent precision and simplified maintenance.

The company selected PROTiM, a Polish machine builder and system integrator operating under the iFormer brand, based on its experience in developing synchronized servo-driven packaging machines.

Integrated Automation on a Unified Control Platform
The completed Tray & Hood packaging line is based on OMRON's Sysmac automation platform. All motion control, logic, HMI, and safety functions were integrated into a single engineering environment.

The machine combines multiple packaging operations within one system, including an XYZ manipulator, a RaceTrack transport system, hood forming, tray application, and a palletizing conveyor. Ten synchronized 1S servo axes coordinate these processes, enabling precise motion control and stable machine operation.

The Sysmac platform allows axis groups to be created and managed within a unified development environment, simplifying machine engineering, commissioning, and future modifications.

Why This Solution Was Selected
The tea producer selected the solution because it combines integrated machine control, precise motion synchronization, and simplified maintenance. Full synchronization of the servo drives supports repeatable packaging operations, while CAM-controlled motion and hot-melt gluing contribute to consistent packaging quality.

Maintenance is also simplified through a single Sysmac Studio project covering the complete machine. Individual drive diagnostic screens and sensor visualization on the 15-inch HMI enable faster troubleshooting and service.

Deployment of the Packaging Line
PROTiM designed and integrated the complete packaging line according to the customer's production requirements. The project included machine design, implementation of the automation architecture, synchronization of the servo system, and integration of safety functions and operator interfaces.

The unified control architecture reduces engineering complexity while making future upgrades and maintenance more efficient.

Results for Production Operations
The automated packaging line enabled the tea producer to reduce dependence on manual packaging operations while improving process consistency across the secondary packaging stage. Precise synchronization of machine movements supports stable, repeatable packaging quality and reliable production performance.

The integrated system architecture also simplifies maintenance and diagnostics by managing control, motion, safety, and HMI functions within a single engineering project. This approach supports efficient plant operation and reduces service complexity.

Edited by Evgeny Churilov, Induportals Media – Adapted by AI.

www.industrial.omron.co.uk