TECHNOLOGIES IN THE CONSTRUCTION OF AUTOMATED PACKAGING AND LABELING LINE SYSTEMS IN FOOD PRODUCTION

Automated control systems in the food industry are designed to ensure stable, safe, and efficient operation of technological lines. Automation gains particular importance at the packaging and labeling stages, where high precision, equipment synchronization, and compliance with regulatory requirements including product traceability and operation with marking systems  are essential.

The packaging and labeling line for sports vitamin drinks in PET bottles represents a complex, multi-level technological system. It includes equipment for label application, DataMatrix code marking, machine vision, automatic rejection, formation of transport packaging, aggregation, and palletizing. To ensure coordinated operation of all units, an automated control system is employed, based on programmable logic controllers (PLCs), visualization systems, and industrial peripherals.

The main task of the ACS is to manage the sequence of operations, control technological parameters, collect data on equipment performance, and respond promptly to deviations. The hardware of automated control systems for packaging and labeling lines consists of a set of technical means that provide control functions, data acquisition, and interaction with technological equipment.

Sensors are the primary elements for data collection in the technological process: they detect bottle presence, position of units, pressure, level, and more. Sensors provide key signals about the product’s status, enabling PLCs and SCADA systems to react to process changes and ensure quality control.

Actuators perform physical actions on the line, such as manipulator movement, rejection, drive control, and start/stop of units. Proper selection of both hardware and software components of the ACS is one of the most important factors for stable operation of the packaging and labeling line.

Additionally, it is worth noting that when designing automated control systems for packaging and labeling lines, the compatibility of hardware and software components plays a crucial role. Mismatched characteristics of sensors, actuators, and controllers can lead to control delays, incorrect equipment synchronization, and reduced overall line productivity [1].

Modern ACS for food production are generally built on a hierarchical principle including field level, control level, and supervisory level. At the field level are sensors and actuators responsible for collecting primary information and executing control actions. The control level is represented by programmable logic controllers that implement control algorithms and ensure interaction among line elements [2].

Thus, the effective functioning of a packaging and labeling line largely depends on the proper selection and coordination of hardware and software automation tools, as well as their scalability and integration into the enterprise’s digital infrastructure.

Programmable logic controllers are the central elements of automated control systems. They collect signals from sensors, process control logic, and generate control actions for actuators.

The Russian industrial automation market offers a wide range of domestically produced PLCs, which is especially relevant under import substitution policies.

When choosing a programmable logic controller to automate the packaging and labeling line, it is necessary to consider not only computational performance but also the specifics of the technological process. Packaging lines feature a large number of discrete signals, a high speed of event processing, and the need to synchronize the operation of multiple mechanisms in real time [1].

Modern PLCs enable implementation of complex control algorithms, including processing signals from machine vision systems, interaction with marking equipment, and management of robotic complexes. Use of controllers supporting multitasking and parallel data processing helps increase system robustness under rising loads [3].

A separate important aspect is PLC redundancy and fault tolerance. Continuous food production means that even brief line stoppages can cause significant economic losses. Using redundant controllers, duplicated power supplies, and network interfaces minimizes the risk of unexpected downtime [4].

Moreover, modern PLCs increasingly perform functions beyond classic control. These include preliminary data processing, storage of technological parameters, interaction with databases, and data transfer to SCADA and MES systems [5]. This reduces the load on higher management levels and improves overall ACS efficiency.

SCADA (Supervisory Control and Data Acquisition) refers to software-hardware systems designed for supervisory control and data collection in automated technological process control systems. SCADA systems enable visualization of equipment operation, data collection and archiving, event and alarm logging, real-time process management, and integration with external systems and databases.

SCADA systems are intended for dispatch control, visualization of technological processes, and data analysis. In the context of packaging and labeling lines, SCADA performs equipment state monitoring, displays operational parameters, and records emergency situations.

During automation of packaging and labeling lines, the SCADA system plays a key role in providing transparency and control over the entire technological process—from label application and DataMatrix code reading to aggregation and packaging operation control. The SCADA system allows operators to monitor line status, respond to errors, analyze equipment efficiency, and make timely decisions based on real-time data.

In modern food production, SCADA systems not only provide visualization and dispatch control functions but also serve as important tools for analyzing technological process efficiency. By accumulating historical data, SCADA helps identify equipment performance patterns, analyze causes of downtime, and improve overall productivity of the packaging and labeling line [1].

Alarm and event management systems are of particular importance for packaging lines. Timely notification of operators about violations of technological parameters, machine vision failures, or marking errors enables prompt response to deviations and prevents the release of defective products [2].

This article reviewed the purpose and structure of automated control systems for packaging and labeling lines in the food industry. Analysis showed that automation solutions possess a high level of functionality and reliability and can be effectively applied to manage filling, packaging, and product labeling lines.