What causes frequent minor stops in packaging lines?

Minor stops often result from servo synchronisation issues, inconsistent PLC logic, and poorly prioritised alarms, all of which reduce throughput and increase operator intervention.

How can PLC restructuring improve packaging performance?

Structured PLC code improves fault handling consistency, simplifies diagnostics, and enables clearer alarm management, leading to more stable line operation.

What improvements were achieved in this project?

The project delivered improved throughput, reduced minor stop duration, enhanced fault history tracking, and greater operator confidence.

Why is alarm prioritisation important in high-speed packaging?

Clear alarm categorisation ensures operators focus on critical issues first, reducing response time and preventing small faults from escalating.

Packaging Automation Case Study

Packaging Industrial Automation reducing fault response

Increasing Throughput and Reducing Fault Response Time

Stratos Control Systems delivered a focused packaging line improvement project to stabilise servo performance, reduce minor stops, and improve fault visibility. By restructuring PLC logic and introducing better performance tracking and alarm prioritisation, the line achieved higher throughput and more confident day-to-day operation.

Automation Challenges for Engineers.webp

01

The Problem

The packaging line experienced servo synchronisation issues, frequent minor stops, poor fault history tracking, and inconsistent PLC structure.

Downtime during shift changeovers was impacting output targets and making fault response slower and less consistent than required for a high-throughput line.

02

Scope of Work

Phase 1 – Audit & Diagnostics

Stratos assessed the motion and control performance issues affecting reliability and throughput.

This included:

Servo motion diagnostics and synchronisation assessment
Review of PLC structure and fault handling approach
Assessment of fault history visibility and operator feedback
Identification of quick-win improvements and structural fixes

Improve Fault Finding and Maintenance.webp

Phase 2 – Optimisation Strategy

A structured improvement plan was created to reduce minor stops and speed up fault response while improving maintainability.

The strategy included:

PLC code restructuring for consistency and clarity
Alarm prioritisation to support faster operator response
SCADA integration for performance and stop tracking
Improved fault history capture for repeat issues

Phase 3 – Implementation

Stratos implemented the updates and validated changes with site teams to ensure improvements were measurable and sustainable.

Implementation included:

Restructured PLC logic and fault routines
Alarm improvements aligned to line priorities
Performance tracking integration and visibility improvements
On-line testing, commissioning, and handover

Packaging HMI Development & Standardisation.webp

03

Platforms Used

The project utilised modern automation technologies, including:

Allen Bradley PLC
FactoryTalk View SE
Servo motion control systems

04

Outcomes & Metrics

Key outcomes included:

28% improvement in line throughput
45% reduction in minor stop duration
Clearer fault visibility and improved fault history tracking
Improved operator confidence and faster response to issues

Testimonial

“The structured approach to PLC logic and alarm management has materially improved our packaging line reliability.”

Maintenance Manager

Stratos Control Systems Ltd Control Panel Refurbishment Upgrade.webp

Frequently Asked Questions

Improve Packaging Line Reliability

Upgrade packaging automation with Stratos Control Systems to reduce stops, improve diagnostics, and drive measurable throughput gains with maintainable PLC standards.

Speak to an Automation Specialist