A food processing equipment manufacturer needed a complete control system for a new industrial tray washing line. The project covered the full cycle from control program design through on-site commissioning and ongoing optimization.
The Challenge
The washing line is a multi-subsystem installation with several interconnected components that must operate in coordination:
- Transfer system — automated tray handling and positioning
- Washing station — tray cleaning with controlled wash cycles
- Safety and communication system — safe operation across all subsystems
- Control panel with HMI — centralized operator interface
Each subsystem has its own I/O requirements, safety considerations, and operating sequences. The control system needed to coordinate all of them while providing operators with clear visibility into the process.
Our Work
We delivered the complete control system across multiple engagement phases:
Design Phase
- Functional design for all subsystems
- Siemens PLC programming with safety integration (ProfiSafe)
- Operator HMI development for process monitoring and control
- Drive integration for conveyor and wash motors
Startup and Commissioning
- On-site startup across 3 equipment units
- Sequential commissioning of each subsystem
- Process tuning and speed optimization
- Operator training
Ongoing Support
- System integration with third-party equipment (Atomha)
- Performance optimization — line speed doubled through control tuning
- Continued troubleshooting and tune-up support
- Digital twin development using PLC-Lab for offline testing
Technology
- PLC: Siemens S7-1200 F-CPU (safety-rated)
- Safety: ProfiSafe integrated safety
- Drives: SEW variable frequency drives for conveyors
- HMI: Siemens operator panel
- Simulation: PLC-Lab digital twin for offline testing and development
- Programming: Structured Text (IEC 61131-3)
Results
The washing line has been in production use with ongoing optimization support. After the initial commissioning, we integrated additional third-party equipment and doubled the line speed through control system tuning alone — no mechanical changes required. The digital twin built in PLC-Lab allows us to test program changes offline before deploying to the live system.
Industry: Food Processing
