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Wireless production-counting and defect-logging system for dairy processing

Wireless production line accounting and defect registration system for dairy processing
June 17, 2026 by
Ričards Sleņģis

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An automated system for four production lines: wireless sensors count finished units, operators log defects with a button, and all data lands in one HMI panel in real time.

4

production lines

24/7

automatic counting

7"

Turck HMI panel

The problem

Without data, production can only be guessed

Before the system was installed, the company had no accurate idea of how much each line produced and where defects occurred. Planning was based on assumptions rather than facts.

 No data on operator productivity

It was unknown how much product each operator produced during their shift.

 Manual defect accounting

Defects and products sent to the laboratory were recorded on paper or not at all.

 No production report

There was a lack of information on how much of a specific product was produced daily, weekly, or monthly.

How it works

Four lines, one overview

Product accounting

On each line, optical sensors Banner QS18VP6AF25QQ8 with background suppression (BGS) function automatically count the passing production.

Defect recording

Banner K50PFAMGRY3Q buttons (IP69K) allow the operator to record defects or products sent to the laboratory. The color changes from green to red, so the operator always knows that the action has been registered.

Wireless data transmission

Banner R70SR2MQ transmitters transmit sensor and button data to the central control unit using the Modbus RTU RS485 protocol at 2.4 GHz frequency. The system uses a star topology: four transmitters send data to one central receiver.

Data representation

All indicators are displayed on the Turck TXT10-P3CV01 HMI panel with a 7-inch touchscreen. Operators see real-time accounting, track defects, and access reports in one place.

 

What the system consists of

System architecture

System components

What the system consists of

4× Production Line → Star Topology → 1× Central Receiver → Turck HMI 10"

What it changes day to day

From assumptions to accurate data

Transparent operator indicators
Output is counted for each operator and each line separately — an objective basis for work evaluation.

Fully digital quality monitoring
Defects are recorded digitally and timestamped, thus eliminating manual document circulation and human errors.

Reliable information about production
Accurate daily, weekly, and monthly data allows for production planning and result analysis.

Real-time remote visibility
Production processes can be monitored remotely, ensuring transparency even outside the factory.

Questions and answers

Frequently asked questions

The implementation of a 4-line system costs under 10,000 euros. The final price depends on the specific number of lines and the number of required sensors.

If a sensor fails, it is simply replaced with a new one.

Yes. The report section allows exporting data in CSV format with filters by date, operator, and product.
Yes. The same accounting and defect registration approach works in any production with separate lines and product flow. We customize sensors and configuration for each object.

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