Shop-Floor Management in High-Speed FMCG Lines: From Solution Batching to 3D Pallet Flow

1. Semi-Finished Solution Batching (Mixer Drop) and Primary FIFO Feeding

In high-speed consumer goods plants, traceability starts in the semi-finished solution preparation room before reaching the packaging line. Mixer Drop screens verify raw material weighings in preparation vessels against loadcell tolerances and release each quality-approved batch (Drop) into the feed queue of compatible packaging lines.

At the primary packaging line entry, operators scan nonwoven fabric, foil reels and packaging batches using handheld RF terminals and cradle scanners. The system enforces FIFO sequence and checks quality hold status to prevent out-of-spec batch consumption.

[1. Mixer Drop (Solution Batching) & Recipe Verification]
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[2. Primary Line Setup, Sanitation & FIFO Reel Feeding]
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[3. High-Speed Production POD, Centralized Inkjet & Live OEE Andon]
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[4. Secondary Packaging, Single/Bulk Pallet Confirmation & Labeling]
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[5. 5-Stage 3D Pallet Flow (Floor → Elevator → 3D Finished Warehouse)]

2. High-Speed Line Operator Screens, Centralized Inkjet and OEE Andon

When a production order starts on a line, the central MES automatically pushes the exact print format, lot number and production/expiry dates to line-mounted Inkjet printers.

Production counts and stop signals from PLC counters feed both the operator downtime-splitting bar and plant-wide OEE Andon boards in real time.

3. Bulk Pallet Management and 5-Stage 3D Warehouse Transfer

Pallets completed at secondary packaging are validated and labeled through single or bulk pallet confirmation screens. On the 3D Digital Twin, every pallet's real-time position and waiting age across Primary, Secondary, Goods Receipt Warehouse, Elevator and Target Warehouse stages are monitored live.