Packaging
Automation for high-speed packaging machines. PLC, Motion Control, HMI and SCADA development for top-level OEMs.
Packaging Machine Automation
We create automation software for packaging machines in the sectors tobacco, food . We use customers' proprietary frameworks to ensure seamless integration.
Development PLC logic, safety and motion on Siemens, Rockwell and Beckhoff platforms with consolidated methodologies.
Specialized augmentation team to support machine builders during peak orders and new developments.
Areas of application:
- •PLC Development: machine logic, sequences, alarm management
- •Motion Control: electronic cams, synchronisms, custom profiles
- •Safety PLC: SIL/PLd logics, functional validation
- •HMI/SCADA: operator interfaces, recipe management
PLC development
Machine logic on OEM framework with proprietary and standard libraries
Motion Control
Electronic cams, multi-axis synchronism and optimized speed profiles
Safety Integration
SIL/PLd compliant Safety PLC with full validation and documentation
Commissioning
Commissioning, FAT/SAT and worldwide on-site support
HMI
We design optimized HMI interfaces for operators and maintainers on high-speed packaging lines with a focus on usability and reduced setup times.
SCADA development for multi-line supervision with production tracking, recipe management and integrated reporting.
Compliance FDA 21 CFR Part 11 for the pharmaceutical sector with audit trail and electronic signature.
Areas of application:
- •Recipe Management: versioning, parameters, audit trail
- •Production Tracking: OEE real-time, KPI, batch record
- •MES Integration: production orders, traceability
- •Compliance: FDA, GMP, electronic signatures
HMI Design
Responsive interfaces for operator panels and industrial tablets
Recipe Management
Recipe management with versioning, parameters and complete audit trail
OEE Tracking
Automatic OEE calculation, downtime analysis and real-time performance
MES Integration
Bidirectional integration with MES systems for orders and batches
Cycle Time Optimization
We analyze and optimize the cycle times of existing machines through motion tuning, operations parallelization and reduction of micro-stops.
Targeted interventions that led to improvements in 10% on cycle times of the previous generation of machines.
Benchmarking and production KPIs to identify optimization opportunities and validate results.
Areas of application:
- •Motion Tuning: acceleration profiles, S curves
- •Parallelizzazione: simultaneous operations, overlap
- •Micro-Fermate: analysis of causes, corrective actions
- •Benchmarking: version comparison, validation
Motion Analysis
Motion profile analysis and acceleration curve optimization
Parallel Operations
Parallelization of operations for maximum cycle efficiency
Micro-Stop Reduction
Advanced diagnostics to identify and reduce micro-stops
Performance KPI
KPI dashboard for continuous performance monitoring
Specialized Augmentation Team
We provide teams of specialized engineers that integrate into the development teams of machine manufacturers.
Consolidated experience with top-tier customers in the industry and other tier-one packaging OEMs.
Ability to operate on multiple orders in parallel with flexible resource management.
Areas of application:
- •PLC Engineers: development on OEM framework
- •Motion Specialists: complex kinematics
- •HMI Developers: interfaces and supervision
- •Commissioning: worldwide support
Dedicated Team
Dedicated engineers with experience on OEM proprietary frameworks
Flexible Resources
Scalability of resources based on order peaks
Multi-Project
Parallel management of multiple orders with coordination
Knowledge Transfer
Structured documentation and know-how transfer
Tobacco Packaging Machines
Creation of new packaging machines for the tobacco sector using the customer's proprietary automation framework. The project involved 6 Oncode engineers on 4 different orders in parallel, with PLC, safety and motion development directly on the testing line.
Challenges Faced
- •Integration into the customer's proprietary framework with rigorous standards
- •Coordination of 6 engineers on parallel orders with stringent deadlines
- •Improved cycle time compared to the previous generation
- •Online commissioning and debugging before delivery to the end customer
Applied Skills
Technologies Used
Results Obtained
- Increased capacity of the customer team with 6 dedicated engineers
- 10% improvement in cycle time compared to the previous version
- Zero defects detected during customer acceptance
- Delivery on time for all 4 orders
Pharmaceutical Blister Line
Development of control software for blister packaging lines in the pharmaceutical sector. The project required compliance with FDA 21 CFR Part 11 regulations, process validation and integration with serialization systems.
Challenges Faced
- •FDA 21 CFR Part 11 and GMP regulatory compliance
- •Integration with serialization and tracking systems
- •Process validation with IQ/OQ/PQ documentation
- •Batch and recipe management with complete audit trail
Applied Skills
Technologies Used
Results Obtained
- Passed FDA audit without critical observations
- Complete integration with Antares serialization system
- 40% reduction in format changeover times
- Complete traceability from the raw material lot to the finished product
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