Vol. 01, Iss. 4 (2024) 158-165, DOI: 10.61552/JSI.2024.04.

004

Journal of Sustainable
Development Innovations
www.jsi.aspur.rs

To Integrate and Optimize the Use of Programmable

Logic Controller in Development of Horizontal Flow
Wrap Packaging Machinery for Industry Needs

Lalit Bhanwrelaa, Jitendra Managrea,*, Naresh Purohit c , Namit Guptaa

aElectrical
and Electronics Engineering, ATC-Factory Automation Lab-MEI. Shri Vashnav Institute of Technology
and Science, Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore, India.

Keywords: ABSTRACT
PLC, Compressor, Heat Controller,
Conveyor, Capacitive Sensor, Sealing This paper focuses on the use of PLC and HMI in the automation
Assembly, Solenoid Switch. industry for a highly effective and versatile horizontal flow wrap
plastic film packaging solution. The machine's functioning and
efficiency are thoroughly evaluated through extensive testing and
* Corresponding author: validation procedures across multiple criteria. The main aim of this
paper is to do the automatic plastic film packaging of any product with
Jitendra Managre
packaging dimensions of 4cm X 5cm. For the process automation the
E-mail: [email protected]
FX5U 32MT PLC of Mitsubishi is used for controlling and automating
the system using ladder logic. The result shows that the developed
Received: 2 June 2024
system provides fully automatic wrap packaging of products and able
Revised: 15 July 2024
to do automatic packaging of 24 packets in one minute. Additionally,
Accepted: 22 August 2024
the results show the increased efficiency of product rate in less time for
automatic packaging system. Finally, it has been observed that the
system is very beneficial for the automatic packaging process using
PLC and the process can be monitored and visualized on a display
screen using HMI. Future advancements are required in the system to
meet industry4.0 needs. By incorporating some smart technologies,
deeper integration with Industry 4.0 principles could boost capabilities
in data analytics, connectivity, and remote monitoring for predictive
maintenance.
© 2024 Journal of Sustainable Development Innovations

1. INTRODUCTION of industries are transitioning to automation.

This paper focuses on implementing an
As industrial automation emerges as a automatic packaging control system within a
worldwide manufacturing trend, the process of process machine system, where the control
packaging stands out as one of its most system will have a significant role in managing
prevalent applications. An increasing number all aspects of the system. The paper explains

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the use of programmable logic controller in Products are fed from the production line to
development of horizontal flow wrap packaging material through this equipment.
packaging machine [1]. The horizontal flow Feeding systems may use conveyors, belts, or
wrap machine is a type of packaging machinery infeed systems adapted to the wrapped
used extensively in the food, pharmaceutical, products. Flow wrap machines unwind and
and cosmetic industries for wrapping products feed packing film. Rolls or reels of film are
in a flexible material such as plastic film [2]. unwound to guarantee continuous material
These machines automate the process of supply during packing [5]. A rectangle shaped
wrapping individual or multiple products in a enclosure is formed by the film around the
continuous motion, creating a sealed package product as it passes through the packaging
around the contents. Horizontal flow wrap process thanks to the horizontal flow wrapper.
machines, also known as horizontal form fill Afterwards, the film is sealed longitudinally
seal (HFFS) machines or flow wrappers, are and transversely using heat sealing techniques,
designed to package a wide variety of products, guaranteeing the package's integrity [6]. In
including bakery items, confectionery, snacks, order to create nicely wrapped packages, the
frozen foods, hardware, and medical devices. extra film is trimmed or cut to size after sealing.
Such mechanism guarantees product safety, The application and packing requirements
sanitation, and display by providing effective, determine whether cutting mechanisms such as
quick packaging solutions. Horizontal flow reciprocating blades are used [7,8].
wrapping originated in the mid-1900s, as Contemporary horizontal flow wrap machines
are outfitted with sophisticated control
packing methods changed. Demand for
systems, frequently incorporating PLCs and
automated and effective packing led to the
HMIs [9,10]. By allowing users to adjust
development of flow wrapping technology,
variables including manufacturing rates,
however it pioneered flow wrapping with their
sealing temperatures, and package sizes, these
packing technology [3]. Typically to boost
systems guarantee accurate and reliable
productivity and speed automation is useful in
packing outcomes [11]. Flow wrap machines
the horizontal wrapping process. Horizontal
are designed with safety as their top priority.
flow wraps machines have evolved to meet
To shield operators from dangers and stop
industry demands for efficiency, versatility, mishaps while in use, technically in design it
and speed. Horizontal flow wrap machine includes guards, sensors, and emergency stop
frames are shown in figure 1, usually made of devices [12]. Completely automated packaging
stainless steel or other durable materials lines that include both upstream and
whereas such machines are stable, durable, and downstream machinery including product
corrosion-resistant, making them suited for feeders, fillers, and labelling systems can
many manufacturing situations [4]. incorporate horizontal flow wrappers [13,14].
Overall, the design of horizontal flow wrap
machines continues to evolve in response to
technological advancements, market demands,
and regulatory requirements, aiming to deliver
reliable, versatile, and high-performance
packaging solutions for a wide range of
industries [15]. Automation enhances
productivity, reduces labor costs, and improves
overall efficiency [16,17].

2. LITERATURE REVIEW

There are a great number of publications that

are being examined, and the contributions that
have been enumerated are available in Table 1.
Fig. 1. Processes of Horizontal Flow Wrap Machine.

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Table 1. Related Contribution of Authors.  Minimize initial investment: Reduce initial

Author’s Name Work description costs for the Horizontal Flow Wrap Packaging
Baroro, M.M., The packaging and material handling Machine to widen its accessibility to various
2014 processes were executed utilizing a PLC businesses.
and an HMI was suggested for the
purpose of control.  Enhance maintenance and repair efficiency:
Algitta, A.A., Deployed an automated packaging Improve processes to minimize downtime and
2015 machine by regulating the conveyor belt ensure continuous, reliable operation of the
with a PLC. machine.
Giberti, H., 2015 This study focuses on the kinematic and
dynamic synthesis of a flying machining  Address environmental concerns: Explore and
device, specifying the drive system and implement sustainable alternatives to
design parameters to ensure flexibility mitigate environmental impacts associated
and large production volumes. The
paper incorporates a flexible design into with plastic packaging materials.
a horizontal wrapping machine.
Gupta, T., 2018 Proposed a solution for reprogramming
the PLC involves interconnecting 3. METHODOLOGY
SCADA and PLC. The design of a
packaging process utilizing 3.1 Description of System
Programmable Logic Controllers (PLC)
and Supervisory Control and Data
Acquisition (SCADA) for remote control Each component in a PLC-based horizontal flow
and monitoring, along with a software wrap packaging machine is essential to the
interface for process visualization, is effective and dependable operation of the
proposed. system. The power supply provides electrical
Gupta, T., 2018 This study examines the control energy to all components of the machine and
specifications of an automated capping
ensures the power requirements for proper
machine, determines the input/output
configuration of the system, constructs operation. The relay module serves as an
a flowchart depicting the primary and interface between the PLC and high-power
secondary programs of the system, and devices such as motors, heaters, and solenoid
finalizes the program and monitoring switches. it enables the PLC to operate these
interface designs in accordance with the
flowchart.
devices safely and effectively. The PLC controls
Ashhab, S., 2020 In order to accurately count the diapers,
the packing machine by carrying out
a PLC-based precise sensor system was preprogrammed instructions to synchronize the
created. The developed packaging functions of different parts. It receives sensor
machine for diapers expedites the input data, processes them using logic that has
production of diapers while reducing
been designed, and outputs signals to operate
expenses.
Sobh, A. S., 2021 Presented a manufactured automatic
heaters, actuators, motors, and other devices.
feeding system for a manually run flow- Pneumatic components including solenoid
packing machine. Automation of the switches, cylinders, and actuators receive
feeding system replaced manual compressed air from the air compressor. These
placement of pieces on the conveyor. pneumatic tools are necessary for operations
Resulting in increased product waste
and occupational injury risk. Automatic including cutting, sealing, producing films, and
feeding mechanism design addresses feeding products. The heat controller controls
these issues. the temperature of heating components used to
seal packaging film, such as rod and circular
Based on the above discussion and related heaters. The products are transported into the
literature survey, this research focuses on the packaging machine by the infeed conveyor and
successful integration and optimisation of HMI then moved through the packaging process by
and PLC technologies to enhance control, the motor conveyor. These conveyors guarantee
monitoring, and user interaction within the a steady, regulated flow of goods, facilitating
machine [18]. But during the literature and reliable, effective packing processes. Pneumatic
discussion of this horizontal flow wrap systems, solenoid switches regulate the
packaging machine we also come to know that compressed air flow to different pneumatic
this paper can also be useful to achieve some actuators and parts. Sensors identify the
following objectives also. existence, location, and condition of goods,

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packing materials, and machine parts, however setup chores. The software has an interface that is
based on the sensor feedback the PLC allows the easy to navigate and is compatible with various
machine for immediate supervision and control programming languages, including structured
of the packing process. Sensors guarantee text, ladder logic, and function bar diagrams. The
precise product placement, appropriate film GX Works3 software is utilized for the purpose of
tension, and prompt execution of diverse designing control logic, specifying input and
machine operations. Products are inserted into output devices, configuring communication
the film, the edges are sealed to produce parameters, and conducting program simulations
individual packages, and the film is folded or prior to deployment on the FX5U PLC.
unfolded as required. When these systems are
operating correctly, products are packaged
precisely and efficiently while retaining their
integrity and aesthetic appeal. The discharge
conveyor moves packaged goods to the next
section of the production line or to packaging for
distribution after receiving them from the
packaging machine.

A continuous wrapping material, commonly a

roll of flexible packaging film, is used by the flow
wrap packaging equipment in this system to
enclose the product in a shut-off package.
Automating and regulating the operation of the
horizontal flow wrap packaging machine is
dependent on the PLC. Executing a programmed
designed particularly for this purpose, the PLC
regulates the entirety of the machine's
operation. The programmed dictates to the PLC
the timing for starting and stopping the motors
that power the machine's components, including
those that unwind films, input products, cut, Fig. 2. Photograph of FX5U 32MT PLC.
seal, and move the conveyor. To monitor the
process and make necessary adjustments to The integration of these components enables the
guarantee consistent packaging quality and effective development and management of a PLC
efficiency, the PLC may also integrate feedback control system. Table 2 presents the technical
mechanisms and sensors. To accommodate specifications of the PLC FX5U.
various products and packaging materials, PLC
programming permits the modification of Table 2. Specifications of FX5U-32MT PLC.
machine parameters including package size, Features of FX5U PLC
speed, and closure temperature. Design and No. of inputs and outputs 16 (maximum)
development of the packaging system were Power supply 100-240 VAC
conducted utilizing FX5U 32MT series PLCs. The Type of output Transistor
FX5U 32MT PLC series, which is utilized in this Consumption of power [W] 30
system, is depicted in Figure 2. Weight [Kg] 0.7
Size in Width [mm] 150
Mitsubishi Electric manufactures the robust and
small-sized FX5U line of programmable logic 3.2 Flow Chart of Methodology
controllers. It controls a variety of operations and
is commonly utilized in industrial automation. Figure 3 displays a flow chart that offers a concise
FX5U PLC programming and configuration are summary of the consecutive procedures required
done with GX Works3 software. GX Works3 is a for the functioning of a PLC-based horizontal flow
software application utilized for the purpose of wrap packaging machine. Each step interacts
program creation and modification, PLC system with various components to ensure efficient and
monitoring and debugging, as well as various reliable packaging of products.

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4.1 Experimental Setup (Hardware Model)

The proposed system has been developed as a

result for optimizing the use of PLC and HMI in
horizontal flow wrap packaging machine. This
hardware description outlines the essential
components of a PLC-based horizontal wrap
packaging machine. Depending on specific
requirements and features, additional
components have been included in the setup.
Figure 4 illustrates the complete hardware model
of the experimental setup.

Fig. 3. Flow Chart of the Process.

The flow chart describes that the packaging

process starts with the power supply, ensuring all
components are operational. Then proximity
sensors detect product presence on the infeed
conveyor, moving products towards film forming.
Film is unwound and formed into a tube around
the product. The horizontal pulling motor
controls film movement. Solenoid switches
manage pneumatic tasks like sealing. Sealing Fig. 4. Photograph of experimental setup.
system activates to seal film edges, regulated by
heaters. Film folding/unfolding creates desired The working of the whole system and function
package configurations. Packaged products are operation of each component are described as
transferred to the discharge conveyor. The follows:
packaging area provides space for loading and
maintenance. The air compressor ensures Power supply activation starts the packaging
pneumatic component operation. Heat controller process by powering all packaging machine
maintains sealing temperature. PLC signals the components. The packaging operation requires
relay module for device activation. The process motors, heaters, controls, and other electrical
stops once packaging is complete. Each step components.
ensures efficient and reliable packaging.
Once the power supply is on, infeed conveyor
sensors detect items. These proximity sensors
4. RESULTS ANALYSIS AND DISCUSSIONS can detect packaged products. The system delays
packing until a product is found. This prevents
This section offers an analysis or interpretation empty packages and maximizes material
of the results obtained from the proposed consumption. The machine's film-forming
research objectives. In this section, hardware segment receives items identified by the sensors.
model of the experimental setup of the developed After unwinding from a roll, the film is shaped
system has been described. Also discussed the around the product. The product is safely
detailed overview of the PLC and HMI integrated enclosed in the packaging material by making a
horizontal flow wrap packaging machine, tube or sleeve. While packing, the horizontal
including its components, functionality, and pulling motor moves the film. It ensures the film
specifications. flows horizontally at a predetermined speed,

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making packing alignment and sealing easier. Open the GX Works3, start a new project and
Sealing is controlled by solenoid switches in configure PLC FX5U. Designed a ladder logic for
pneumatics. Switches control cutting and sealing proposed problem in GX Works3 and keep the
pneumatic actuators. Programmable logic in the programmed in simulation mode. Using similar
PLC activates solenoid switches to precisely input/output addressing, HMI screen was designed
control pneumatic processes. After placing the in GT designer3 environment. After labelling the
product in the film tube, the sealing mechanism similar input/output and tags, interface the HMI
seals the film edges lengthwise. Circle and rod and activate the simulation mode for the designed
heaters manage sealing temperature to ensure HMI screen. The IP addresses of HMI and personal
film adherence and a tight seal around the computer or laptop should be same. Every memory
product. By folding or unfolding the film, film location and element on the PLC is given a tag name
folding and unfolding technology determines during coding, and these tag names are connected
packing designs. This stage may require folding to various HMI screen events and properties. It is
arms or guides to form the film. possible to add and edit every PLC tag. The all the
PLC tags and switches, which are used in the coding
PLC and HMI signal relay module for device are shown in table 3.
activation, controlling numerous components
based on preset logic. After packaging, the Table 3. PLC tags and switches.
process concludes, and the products are ready for Tags/switches Description
distribution. From product detection to sealing X0 START (whole system)
and discharge, the process provides efficient and X1 Start
reliable packing. X2 Stop
Y1 Infeed conveyor
4.2 Software Simulation Results Y2 Belt Sealer
Y3 Solenoid valve upper
The entire programming for the developed Y4 Solenoid valve down
system is conducted exclusively on the FX5U Y5 Output conveyor
32MT PLC platform using the GX Works3 T0 On delay belt sealer
simulation software. The selection of the PLC T1 On timer, solenoid valve up
FX5U series is motivated by its incorporation of T2 Dealy timer for solenoid valve
simulation capabilities, which streamline the down
monitoring process for the diverse parameters T3 Sealing delay timer
inherent in the proposed model. Ladder logic, a T4 Conveyor timer lower
programming language employed, M0 Internal relay
accommodates graphical representation of
programming functions, closely resembling the After completing the ladder programming, it is
symbols utilized in conventional hardwired required to establish communication between
control diagrams. For the completion of the the PLC code and HMI for similar input/output
implemented system, multiple ladder networks tags. The ladder logic programming has been
or rungs are used. There are also many implemented by using above similar I/O
instructions are used for the input and output addressing, tags and switches for specified task.
module. Input module has some push buttons, The PLC program is shown figure 5.
toggle switches and sensors. And in output
module some motors, actuators, conveyor
system and many more are present.
Implementing networks for all these, many
instructions are used like timer, counter,
holding, set, and reset etc. Mitsubishi's
HMI/GOT2000 controls and monitors the
system's ladder logic, which GT designer3
software visualizes. The HMI system may
monitor and control hardware model operation
with marked start and stop buttons. Connecting
the PLC and HMI requires these steps: Fig.5. PLC program in GX Works3 simulation software.

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Once the hardware connection between the PLC system performs accurately and precisely. All
and HMI has been successfully established, the system components are well-interfaced, efficient,
simulation phase can be conducted to simulate performing properly, sequenced well, and synced
the I/O addressing. This will allow for easy with code instructions. Table 4 compares
monitoring and control of the specified logic, as manpower-based and PLC-based automatic
illustrated in figure 6. packaging system product rates over time.

Table 4. Product rate comparison

Time Product Product packaging
packaging (with (Automatic)
manpower)
10 seconds 2.5 4
1 minute 15 24
1 hour 900 1440
1 day 21600 34560

The packaging machine's effectiveness, speed,

and efficiency increase when PLC and HMI are
added to make it automatic. In conclusion, the
Horizontal Flow Wrap Packaging Machine met
objectives well. It exceeded speed and
throughput targets while retaining precision.
The machine's fast changeover mechanisms
Fig. 6. Connection between PLC and HMI/GOT2000
minimized downtime and accommodated
Push Buttons (X0) and (X2) activated and goods of varied sizes and forms. Seal integrity
deactivated the Packaging system. The upper was maintained, with robust seals across
motor of the infeed conveyor (Y0) moves the materials. Operators needed less training due
upper conveyor belt, which sequentially to the simple interface.
transfers plastic materials to the desired place.
Sensor mechanism and other component
functions commence when pushbutton (X1) is 5. CONCLUSION
pressed. After detecting plastic at the
designated spot, the sensor stops the lower The integration and effective use of PLC and
conveyor belt and activates the upper belt to HMI enabled horizontal flow wrap automatic
seal and sever the plastic. The infeed motor packing machines. This study presents a highly
efficient and adaptable plastic film packaging
drives the infeed conveyor belt (Y0) to package
products, which are sealed, sliced, and dumped system using a Programmable Logic Controller
in the collection point. The instruction (M0) (PLC) and Human Machine Interface to fulfil the
urgent demand for automation in diverse
acts as an internal relay to demonstrate
memory bit function throughout this operation. industries. By detailing the design,
This process takes one minute and counts development, construction, and testing
sample packaging. Disconnect at completion of processes, a horizontal flow wrap packaging
process till pushbutton (X2) pressed. machine with PLC integration was created. This
system uses GT designer3 for HMI visualization
and monitoring and the FX5U 32MT series PLC
This program uses timing to delay component
activation and measure product packing time. for ladder logic design. Multiple evaluations
This method produces four packets of 4cm X 5cm showed the machine's excellent performance. It
plastic packing products in 10 seconds. Plastic automated 4cm x 5cm wrap wrapping at 24
packet packaging takes 2.5 seconds for 01 packets per minute. The employment of PLC
package. Manual packaging requires at least 4 and HMI technology improves control,
seconds and must be done continuously. The HMI monitoring, and human interaction.
controls and visualizes the entire system. It was
observed during the procedure that the designed The machine also smoothly transitions between
product shapes and sizes, so efficiency can be

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improved. Further development could improve [7] R. Mofidul Shabbir and A. Podder, "Design and
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