Project Snapshot | Food Processing and Packaging OEM

Client: Food processing and packaging OEM – Pizza base line
Industry: Food processing and packaging
Location: Dublin, Irland
Services provided: Electrical and control system design for pizza base forming and packaging machine with conveyor system, including inspection and weighing integration
Software used: Eplan Pro Panel
Inspection & quality: Keyence imaging system and inline weighing system
PLC & HMI: Allen Bradley CompactLogix 5390 and PanelView Plus 7 HMI
Key result: Automated pizza base production and packaging with integrated quality checks and consistent product handling across the conveyor line
Duration: 4 months from design to commissioning support

Client & Project Background

The client manufactures special purpose machines for food applications and required a complete control solution for a new pizza base making and packaging machine with integrated conveyor handling. The goal was to automate dough-formed pizza bases through baking, cooling, inspection, weighing, and packaging while maintaining strict quality standards and repeatable throughput. APC Engineering Services was engaged to design the control panels, conveyor controls, vision and weighing integration, and HMI/PLC logic architecture using Eplan Pro Panel and Allen Bradley hardware.

Challenge / Requirements

The line had to coordinate multiple functions: pizza base transfer on conveyors, positioning for inspection and weighing, rejection of out-of-spec products, and feeding into the packaging section.
Quality and compliance requirements demanded non-contact inspection of each pizza base using a Keyence vision system plus weighing to verify product mass before packaging.
The client needed a compact, hygienic control panel and wiring design compatible with the food production environment, while ensuring easy maintenance and washdown considerations.
PLC and HMI programming on Allen Bradley hardware had to provide clear status, alarms, recipe handling, and manual/auto controls for operators.

Solution (APC approach)

1. Design & Panel Engineering

Used Eplan Pro Panel to develop detailed electrical schematics and 3D panel layouts for the main control panel and any local enclosures, ensuring clean segregation of power and control circuits and suitable component placement for food-area installation.
Modeled cable routing, terminal layouts, and space for future I/O expansion in Pro Panel, simplifying panel building and field wiring.

2. Conveyor Control and PLC/HMI

Implemented conveyor zone control, product tracking, and positioning logic in Allen Bradley PLC, synchronizing conveyor speeds and stops with inspection, weighing, and packaging operations.
Developed HMI screens (Allen Bradley) for machine overview, conveyor status, inspection and weighing results, alarms, and recipe management to adjust base size, weight ranges, and packaging counts.
Structured PLC program using modular routines (conveyor, inspection, weighing, reject, packaging) for easier troubleshooting and future enhancements.

3. Inspection, Weighing, and Quality Integration

Integrated the Keyence imaging system mounted over the conveyor to inspect each pizza base for dimensions, shape, toppings presence (if applicable), and surface defects, sending pass/fail and measurement data to the PLC.
Connected the weighing system to the PLC to validate each pizza base against configured weight limits, with out-of-range units automatically diverted or rejected.
Coordinated vision and weighing decisions with diverter or reject mechanisms on the conveyor to prevent non-conforming products from reaching the packaging station.

Results & Benefits

Delivered an integrated control and inspection solution that automates pizza base handling from forming to packaging with consistent product quality and reduced manual checks.
Improved quality assurance through Keyence-based vision checks and inline weighing, allowing immediate rejection of defective or out-of-spec pizza bases before packaging.
Enhanced operator usability with Allen Bradley HMI screens providing clear production data, quality metrics, and alarms, leading to faster intervention and reduced downtime.
Created a scalable machine platform: the same control architecture can be adapted to different pizza sizes, formats, or future toppings and packaging variations.

Tools & Technologies Used

Design: Eplan Pro Panel for 2D schematics and 3D panel layouts, terminal diagrams, wiring lists, and enclosure modeling tailored to food production environments.
PLC & HMI: Allen Bradley PLC and HMI hardware (e.g., PanelView family) for machine control, recipe management, and operator interface on the conveyor-based pizza line.
Inspection & weighing: Keyence imaging system for vision-based inspection and an inline weighing system for mass verification of each pizza base.
Application domain: Food processing and packaging automation, with conveyor-based handling and integrated quality control.

“APC Engineering Services delivered a robust control and inspection solution for our pizza base making and packaging machine. Their Eplan Pro Panel design, Allen Bradley PLC/HMI programming, and seamless integration of Keyence vision and weighing systems have significantly improved our product consistency and reduced manual quality checks. The system is operator-friendly and flexible enough to support future product variants.”

Case Study