How SCADA System Helped Improve Our Stretch Wrap Machines

Our journey of developing stretch wrap machines began with the first-generation model, controlled by a PLC (Programmable Logic Controller) system. This stand-alone machine efficiently performed its intended operations but lacked connectivity and data handling capabilities. The highlight of this early model was the inclusion of a built-in scale, simplifying the process by allowing users to wrap and weigh pallets simultaneously.

Our second-generation machine introduced height measurement, further enhancing the functionality. By the third generation, we had consolidated all operation buttons into a single, user-friendly touch screen panel, streamlining the machine’s usability. However, despite these advancements, the reliance on PLC presented a significant limitation—poor communication with other devices. As a result, operators still needed to manually record weight and height data, then physically deliver it to the shipping department to prepare documentation, which was inefficient.

The turning point came with the integration of a SCADA (Supervisory Control and Data Acquisition) system. SCADA not only excels at controlling machine operations but also at generating, storing, and distributing data. By transitioning from PLC to SCADA, we maintained the high operational standards of the machine while eliminating manual data handling. The system now instantly transmits weight and height data to the appropriate departments.

We didn’t stop there. Cameras and laser systems were added to capture images and videos for documentation and precise 3D measurements of pallets. To further increase efficiency, we incorporated automatic film cutting and mounting, allowing workers to operate the machine without leaving their forklifts. SCADA has since been implemented in various other products, delivering significant improvements and adding great value to our customers.

In conclusion, the integration of the SCADA system has revolutionized the efficiency and functionality of our stretch wrap machines. By addressing the limitations of PLC systems, SCADA has enabled seamless data handling, automated processes, and enhanced precision through advanced technology like cameras and laser measurements. These improvements not only streamline operations but also reduce manual labor, ensuring that workers can focus on other tasks. As we continue to innovate and incorporate SCADA into more of our products, we remain committed to delivering enhanced value and convenience to our customers, paving the way for a more efficient and connected future.