The Challenge
A high-output U.S. manufacturing facility, responsible for processing and packaging large volumes of product for outbound logistics, faced persistent challenges with one of its critical palletizing systems. Though the mechanical portions of the equipment remained in serviceable condition, the control system had become a growing point of failure.
The original OEM control panel was based on a legacy PLC and servo drive platform that had become increasingly unreliable. Technicians were forced to perform frequent manual resets, and troubleshooting was difficult due to a lack of real-time system diagnostics. Operators often had to guess the root cause of issues based on vague indicators or historical fault patterns.
Additional concerns included:
- Limited replacement parts availability due to hardware obsolescence
- No remote access capabilities for engineering or technical support
- Lack of integration with the plant’s broader networked systems
- A user interface that was outdated, difficult to navigate, and provided little useful insight
Since the palletizer was a key link in the packaging and shipping process, downtime had an immediate impact on fulfillment schedules. The operations team needed a fast, reliable solution that wouldn’t require full equipment replacement or weeks of downtime.
The Solution
DSI Innovations was selected to engineer and implement a turnkey controls retrofit that modernized the automation system while preserving the mechanical investment in the palletizer itself.
The project included:
- Replacement of the legacy PLC with a modern, open-architecture controller
- Integration of new servo and drive hardware tailored to the existing mechanical setup
- Design and fabrication of a new control panel, fully documented and labeled for future maintenance
- Development of a user-friendly HMI, providing intuitive navigation, real-time status, and clear fault messaging
- Network-enabling the entire system with Ethernet/IP to support future SCADA dashboards and remote troubleshooting
To reduce the risk of extended downtime, DSI conducted extensive pre-deployment testing and programming offsite. The on-site installation and commissioning were completed on a tight timeline with coordination from plant maintenance and production leadership.
The Results
The controls upgrade delivered rapid and measurable results:
- Significant reduction in unplanned downtime, improving system throughput and production predictability
- Faster issue resolution, thanks to intuitive HMI fault tracking and status indicators
- Improved technician efficiency, supported by a cleanly documented system and logical control structure
- Future-readiness, with networked connectivity that enables remote diagnostics and future SCADA integration
- Protected capital investment, allowing the facility to retain a functioning mechanical asset while modernizing its automation layer
By modernizing the palletizing system’s controls, the facility improved reliability at a critical point in its outbound packaging process. The success of the project demonstrated the value of targeted automation upgrades—particularly for organizations seeking to extend the life of equipment and reduce support costs without large-scale capital replacements.
For manufacturers and facilities handling high volumes of outbound product, aging palletizing systems can become a bottleneck. DSI Innovations offers targeted retrofit solutions that extend equipment life, minimize downtime, and prepare operations for scalable digital transformation.
