Automated Packaging Line

Salas O’Brien partnered with a top chemical manufacturer to provide detailed design, engineering, construction management, and start-up support for its new automated packaging line.

CONCEPT & IDEATION
We began the project by developing a tailored conceptual design, drawing on our expertise in process automation and packaging solutions. Our team conducted thorough site visits and stakeholder interviews, confirming we fully understood the client’s functional requirements and identified key challenges with their existing process. Leveraging our collaborative approach and technical insight, we delivered ten innovative concepts to drive operational efficiency, reliability, and value, while outlining the features, benefits, and critical study items for decision-making.

TURNKEY SOLUTION
Based on our conceptual design, we provided a full turnkey solution. Our team led the integration of a fully automated packaging line, selecting and implementing advanced equipment such as a bulk bag unloader, twin-auger product scale, dust collection, bag filler system, bag sealer unit, vertical bag conveyor with kicker, horizontal bag conveyors, check weigher with reject, bag flattener unit, bag centering belt, print-n-apply labeler, and robotic palletizing system. Each system operates seamlessly through a ControlLogix programmable logic controller (PLC), a PanelView Plus 7 Performance Human Machine Interface (HMI), and a Supervisory Control and Data Acquisition (SCADA) system, all integrated via Ethernet Industrial Protocol (IP) for robust connectivity and streamlined automation. We also provided strategic layout planning to support future expansion, positioning our client for ongoing growth and operational success.

CUSTOM EQUIPMENT FABRICATION
During the project, the client received a spreader bar that would not lift the product high enough. After some investigation, our team took measurements and custom-designed a spreader bar to fit the client’s needs. Our structural team reviewed and stamped the drawings, and our stainless-steel fabrication team used the design to create the new bar specifically for this project. We also managed all the procurement for power, instrumentation and controls, Information Technology and Operational Technology (IT/OT), and programming equipment. Throughout the construction phase, we provided ongoing guidance and start-up support to prepare the new packaging line for operation.