Pallet Tracking

The customer requested a system that validates the product running on the line, prints and applies a label to a pallet, validates that label, and interacts with their ERP to create inventory. The client installed 7 print and apply printers for each runoff with 1-3 lines per runoff, thus multiple lines shared a single printer. Pallet tracking was critical to ensure the line and case count data was correct for each pallet arriving at the printer. CDSL installed a plantwide SCADA HMI system using Inductive Automation’s Ignition platform. Using an intermediary database to communicate with the customers Microsoft D365 ERP, CDSL displayed the relevant lines’ production orders to the palletizer operator to select on product changeover. A barcode scanner was used to read the case barcodes on the finished pallet, validating against the selected production order for that line. Once validated, the relevant data was sent to the labeler to generate a label containing 4 barcodes (License Plate Number, Order Number, Item SKU, Case Quantity) and applied to the pallet. This label was also validated to ensure all 4 barcodes were correct and the label was applied to both the front and the side of the pallet. Once this validation was completed, a database entry was created generating inventory for the plants ERP. Fork truck operators could then scan the pallet’s barcode and assign a destination at the end of the runoff conveyors.

Data validation and recording is becoming increasingly important to our consumers, especially in the food and beverage industry. Up until this project, this customer’s only way of linking the business side to the production side was a paper log entry from the operator at the end of the shift. Now, the business side knows in real-time, down to the case how many more cases are needed before a production order is complete. This information allows the business to make real time decisions, while reducing overages and shortages, quality hold periods and product recall periods.