Consumer Packaging & Consumer Packaged Goods
DSI Innovations brings reliable automation systems and solutions to the Consumer Packaging and Consumer Packaged Goods (CPG) industries, optimizing packaging lines and driving operational efficiency. Your success is our mission…From robotic packaging systems to automated labeling and coding, our solutions ensure fast, precise, and scalable production.
We offer advanced quality control and inspection systems to help you maintain the highest standards, along with product traceability solutions for complete visibility throughout the supply chain. Whether it’s warehouse automation or inventory management, our integrated systems help you meet the demands of a dynamic marketplace with speed, accuracy, and reliability.
Our Consumer Packaging & Consumer Packaged Goods Capabilities
Packaging Automation & Control
- PLC/HMI/SCADA Implementation: Developing robust control strategies, operator interfaces, and real-time monitoring for packaging machinery.
- Filling & Sealing Automation: Optimizing filling volumes, sealing temperatures, and cycle times to maintain product integrity and throughput.
- Labeling & Coding Control: Integrating label print-and-apply systems with variable data (dates, barcodes, lot numbers) for traceability.
- Cartoning & Case Packing: Automating carton erection, product loading, and final case sealing for efficiency and consistency.
- Conveyance & Line Balancing: Synchronizing conveyors, diverters, and merges to maximize line throughput and minimize bottlenecks.
- High-Speed Sorting: Using sensors, diverters, or robotics to quickly separate products based on size, weight, or identification.
Thermoforming & Extrusion
- Complete Extrusion Line Integration: Designing and implementing end-to-end extrusion processes, from raw material feeding to finished sheet or film output, ensuring consistent melt quality and throughput.
- Multi-Zone Heating & Forming: Utilizing precise, multi-zone PID controls and automated forming cycles to maintain uniform temperatures and achieve consistent product dimensions.
- In-Line Quality & Thickness Monitoring: Incorporating sensors, gauges, and vision systems to measure sheet thickness, detect defects, and generate real-time data for proactive adjustments.
- Automated Thermoforming & Trimming: Coordinating servo or pneumatic systems to streamline forming, trimming, and stacking operations, reducing cycle times and labor costs.
- Integrated Downstream Packaging: Linking formed packaging components—such as trays, cups, or lids—directly into filling, sealing, and labeling lines for a seamless operation.
- Advanced Process Control & Data Analytics: Deploying SCADA/HMI systems to gather real-time production metrics and employing predictive analytics to reduce downtime and improve efficiency.
Extrusion Systems
- Modernizing Extruder Controls: Replacing obsolescence PLCs and control panels with next-generation hardware for improved reliability and long-term support.
- Large VFD Upgrades: Eliminating antiquated drives, integrating high-capacity VFDs to achieve more precise speed regulation and energy efficiency.
- Advanced HMI/SCADA Integration: Providing real-time monitoring of extrusion parameters (screw speed, melt temperature, output rate) alongside historical trend analysis.
- Material Feeding & Dosing: Automating gravimetric or volumetric feeders to ensure accurate resin blending and consistent product formulation.
- Parallel Commissioning & Rollouts: Deploying phased installation strategies to minimize production interruptions while upgrading large extrusion lines.
- High-Speed Sorting: Using sensors, diverters, or robotics to quickly separate products based on size, weight, or identification.
Web Handling Systems
- Precision Tension Control: Utilizing load cells, dancers, and PID loops to maintain uniform tension across winding, unwinding, and intermediate stations.
- Synchronizing Multiple Drives: Coordinating drive speed commands and torque sharing among rollers, nip stations, and winders for smooth web flow.
- Registration & Edge Position Control: Integrating sensors and actuators (lateral guides, vision systems) to correct alignment and prevent material drifting.
- Automatic Splice & Transfer: Implementing motorized splice tables and turret winders for seamless roll changes without stopping the line.
- High-Speed Web Inspection: Employing cameras and defect detection software to identify flaws like wrinkles, tears, or color inconsistencies on the fly.
- Data Logging & Analytics: Recording web tension, roll diameter, and splice events for performance reviews, waste reduction, and predictive maintenance.
Line Integration & Optimization
- Turnkey Packaging Lines: Coordinating multiple OEM machines—fillers, cappers, labelers, case packers, etc.—into a seamless line.
- Equipment Selection & Sourcing: Guiding clients in choosing the right blend of equipment to meet speed, volume, and product requirements.
- Line Controls & Communications: Standardizing protocols (Ethernet/IP, ProfiNet, OPC UA) to ensure all machines communicate effectively.
- Throughput & OEE Improvement: Analyzing cycle times, downtime events, and performance data to boost overall equipment effectiveness.
- Production Line Simulation: Modeling layout and flow in software to predict bottlenecks before physical installation.
- Scalable & Modular Designs: Building lines that can be easily expanded or reconfigured for new products and changing demands.
Material Handling & Robotic Systems
- Robotic Palletizing & Depalletizing: Integrating robotic arms with end-of-arm tooling for stacking, unstacking, and precise product placement.
- Pick & Place Applications: Utilizing high-speed delta or SCARA robots for accurate product sorting, feeding, or orientation.
- Automated Guided Vehicles (AGVs) & Autonomous Mobile Robots (AMRs): Streamlining material flow between packaging stations or warehouses.
- End-of-Line Automation: Installing stretch wrappers, pallet conveyors, and robotic pallet labeling to expedite shipping.
- Custom EOAT (End of Arm Tooling): Designing grippers, vacuum cups, or specialized fixtures to handle diverse product shapes and packaging materials.
- Safety Integration: Incorporating light curtains, safety scanners, and fencing to protect workers and comply with standards (ANSI/RIA).
Quality Control & Vision Inspection
- Machine Vision Integration: Implementing cameras, sensors, and image processing software to detect defects, missing labels, or incorrect fill levels.
- Barcode & QR Code Verification: Ensuring that all products are correctly labeled and scannable for distribution and traceability.
- Weight & Fill Level Monitoring: Using checkweighers or inline scales to confirm package contents and reduce overfill or underfill.
- Seal Integrity & Leak Detection: Automating tests for pouches, bottles, or vacuum seals to maintain consumer safety.
- Color & Printing Quality: Verifying label color accuracy, print clarity, and brand consistency.
- Reject & Divert Systems: Incorporating automated re-routing of non-conforming products to maintain quality and throughput.
Track & Trace Solutions
- Serialization & Product Coding: Ensuring each unit has a unique ID for traceability from production to retail.
- Warehouse Management Integration: Linking production data to WMS/ERP systems for real-time inventory updates.
- RFID & Barcode Tracking: Tagging products or pallets to monitor movement across supply chain stages.
- Chain-of-Custody Documentation: Capturing data for raw materials, production steps, and shipping details to comply with audits.
- Recall & Compliance Management: Simplifying the process of identifying and isolating specific batches or lots if needed.
SCADA, Data Analytics & MES Integration
- Real-Time Production Monitoring: Capturing key metrics (rate, rejects, downtime) to identify inefficiencies in the packaging line.
- Data Historian Implementation: Storing high-volume production data to support long-term trend analysis and audits.
- Reporting & Dashboards: Generating automated shift reports, OEE dashboards, and KPI summaries for management.
- MES/ERP Connectivity: Bridging the gap between plant-floor operations and enterprise systems for scheduling, order management, and inventory.
- Predictive Maintenance Analytics: Using machine data to forecast component wear or failures, reducing unplanned downtime.
- Cybersecurity & Network Hardening: Protecting operational systems and data against external threats or unauthorized access.
Regulatory & Safety Compliance
- OSHA & NFPA Compliance: Implementing machinery safety standards, lockout/tagout procedures, and electrical safety best practices.
- Food-Grade & Sanitary Design: Using stainless steel enclosures, washdown-rated equipment, and hygienic panel designs where applicable.
- Hazardous Location Solutions: Addressing Class/Division or ATEX requirements for flammable or combustible dust environments.
- Risk Assessments & Safety Audits: Evaluating equipment layouts, guarding, and controls to minimize operator risk.
- Documentation & Safety Validation: Providing risk assessment reports, safety PLC logic documentation, and operator safety procedures.
Control Panel Design & Fabrication
- Custom Enclosure Fabrication: Designing UL- or CE-certified control panels optimized for packaging environments.
- Component Selection & Layout: Specifying PLCs, drives, and I/O modules from leading manufacturers for reliable performance.
- Cable Management & Labeling: Ensuring clear identification of wires and terminals to simplify maintenance and troubleshooting.
- Pre-Delivery Testing (FAT): Conducting thorough inspections and I/O checks to confirm functionality before shipment.
- On-Site Commissioning (SAT): Verifying system performance in real operating conditions and fine-tuning if necessary.
- Documentation & Drawings: Providing electrical schematics, panel layout diagrams, and BOMs for maintenance and compliance.
Upgrades, Retrofits & Migration
- Legacy Migrations & Obsolescence: Removal of end-of-life hardware and unsupported systems to prevent downtime risks, ensure replacement parts availability, and secure long-term reliability through modern, vendor-supported solutions.
- Hardware & Software Upgrades: Incorporating new controllers, drives, sensors, or automation software to boost system reliability, integrate modern features, and future-proof operations.
- Retrofits & Expansions: Enhancing or reconfiguring existing equipment and systems to meet evolving production demands, address obsolescence, and capitalize on new market opportunities—all while managing costs and downtime through planned rollouts.
- Parallel Testing & Commissioning: Running new solutions in tandem with existing setups to minimize operational interruptions and verify functionality before full cutover.
- Hardware & Software Standardization: Unifying multiple control platforms, operating versions, and communication protocols to simplify maintenance, reduce training overhead, and streamline spare parts management.
- Phased Implementation Strategies: Scheduling major updates—mechanical, electrical, or software-related—over planned outages or staggered deployments, ensuring production continuity and optimized resource usage.
- Post-Upgrade Support & Optimization: Providing ongoing support after modernization, including system tuning, operator training, and performance reviews to ensure a smooth transition and long-term success.
Maintenance & Support Services
- Preventive Maintenance Programs
Regularly scheduled inspections and servicing to minimize downtime and extend equipment lifespan.
- 24/7 Technical Support & Emergency Response (with Support Contract)
Round-the-clock assistance to address urgent issues, available to clients who opt for a support contract.
- Post-Project Support
Included with every project to ensure a seamless handover and immediate troubleshooting once the system goes live.
- Field Services
Rapid dispatch of technicians to diagnose equipment issues, perform repairs, and restore functionality—minimizing disruption and downtime.
- Remote Monitoring & Troubleshooting
Real-time tracking of system performance to detect and resolve potential issues before they escalate.
- Staff Augmentation
Access to skilled professionals to fill short-term or specialized staffing needs for ongoing or complex projects.
- Software & System Upgrades
Regular updates to maintain optimal performance, ensure compatibility, and address emerging security concerns.
- Employee Training & Knowledge Transfer
Comprehensive support for in-house teams, covering best practices and hands-on training.
- Compliance & Safety Support
Guidance on meeting regulatory requirements and maintaining best practices for safe operation.
- Lifecycle & Asset Management
Proactive planning for equipment upgrades and replacements to optimize total cost of ownership.
Featured Projects
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CUTTING COSTS, BOOSTING EFFECIENCY: A Paperless OEE System Built for Growth
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FROM MANUAL TO MOBILE: Paperless OEE System Drives Efficiency in Fab Deck Welding
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REVITALIZING PRODUCTION: Control System Upgrade
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PRESSING FORWARD: Future-Ready Automation for the Packaging Industry
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