Wireless Production Counting System for Dairy Manufacturing
Automated monitoring system for 4 production lines with wireless Modbus RTU connectivity, providing accurate production counting, defect tracking, and operator productivity analysis.
Client Challenges
No Operator Productivity Data
Unknown how many products each operator packages per shift.
Manual Defect Tracking
Defects, repackaged items, and laboratory samples not systematically recorded. Data written on paper or not tracked at all.
No Production Overview
No information on how many units of each product were manufactured per day, week, or month. Planning based on assumptions.
Installed Solution
How the System Works
Product Counting
Optical sensors BANNER QS18VP6AF250Q8 with background suppression (BGS) function were installed on four production lines to automatically count products passing through.
Quality Control Interface
BANNER K50PTAMGRY3Q pushbuttons (IP69K rated for harsh environments) allow operators to flag defective products. The programmable button provides instant visual feedback — changing from pulsing green to red when pressed, so operators always know their input was registered.
Wireless Data Transmission
Banner
R70SR2MQ
wireless transmitters send all sensor and button data to the central HMI panel using Modbus RTU RS485 protocol at 2.4GHz frequency. The system uses a star topology: 4 transmitters feeding into one central receiver.
Simplified Installation
Signal splitters (VB2-FSM4.4-2FKM4 and CSB-M1250M1250-T) dramatically reduce cable requirements and eliminate the need for traditional electrical panels — cutting installation time and complexity.
Operator Display
All production data is displayed on the Turck TX710-P3CV01 HMI panel — a rugged 7-inch touchscreen designed for industrial environments. Operators can view real-time counts, track defects, and access production reports from one central location.
System Architecture
From improved operational visibility to stronger data-driven decision-making, the achieved results reflect a structured approach to process optimization and long-term business efficiency, with a scalable system architecture that can be easily extended across additional production lines to support sustainable and long-term growth.
Automatic output tracking per operator and production line, creating a clear, objective basis for performance evaluation.
Defects and reworked products are logged digitally with timestamps — eliminating manual paperwork and human error.
Accurate daily, weekly, and monthly production data available for analysis, reporting, and operational planning.
Up to three users can monitor production live from the office, ensuring full visibility of shop-floor activity.
Results Achieved
HMI Functionality
Operator Interface
Operator and Product Selection Screen
At shift start, operator selects themselves from the list, and which product is currently being produced on the line
Production Count and Exception Logging
Real-time display of accumulated product counts, with a dedicated interface for logging defects, reworked items, and products sent to the laboratory.
Reports Section
CSV export and filters by date, operator, product
Want a similar solution?
We'll design a customized production monitoring system for you.
Q&A
A 4-line system implementation costs under €10,000. The final price depends on the specific number of lines and required sensors.
Depending on the operator's education level and experience with similar systems – typically 1-2 weeks. The system is designed intuitively to facilitate daily work in the production facility.
If a sensor breaks down, it's simply replaced with a new one.
Yes, the system can be expanded after initial implementation. You can add up to ~49 lines maximum.
However, when expanding the system, you need to consider:
- Product flow speed in each line
- Overall system architecture
We'll help assess the optimal solution for your production facility's specific needs.