We recently successfully completed a project in Malaysia to design, install and commission a security printing product serialization and reconciliation system. The brief was to interface with a Leibinger CIJ printer and a SQL server in order to print 2D bar code serial numbers on the product, and map product information from the process onto the serial number into the database. The database is then used on subsequent processes for removal of waste and for supply to the customer of a manifest.
At the heart of the control system was a Beckhoff IPC and Beckhoff HMI Server, using TCP/IP commands to the printer and bar code scanners, and SQL commands to the database. The Beckhoff communicated via its TF6310 TCP/IP client / server function https://www.beckhoff.com/en-au/products/automation/twincat/tfxxxx-twincat-3-functions/tf6xxx-connectivity/tf6310.html, and TF6420 database server. Thin clients were installed at various locations throughout the plant for visualization of the product location in the plant and also detailed product information.
Datalogic Matrix 300N readers were used for reading back the 2D codes https://apps.datalogic.com/e-catalog/ec-Matrix-300N.aspx
Typical for security printing and pharmaceutical / GMP applications, security and traceability were vital to this application, and it was achieved with strong password protection, user management and audit trails.
Coral Process Solutions were responsible for
- System design
- Hardware design
- SQL database architecture
- Software
- Commissioning
- Training
External contractors were used for electrical enclosure manufacture and installation.
The system was tested and commissioned and is now fully deployed and used in production with no-read rates of <0.00001% which exceeds normal product serialization no-read rates.
The system is fully scaleable in the future to allow for additional information to be associated to each item other than product quality information. There are future plans to map full process variables associated with each individual unit, onto the bar code entry in the database so that a complete production history can be archived and recalled.
See our main control systems page for more details https://coralprocesssolutions.com.au/services/control-system-engineering/
