References

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12/2018 – 02/2019

Track & trace for cartoner

Germany (DACH): Siemens S7-315-2 DP, MicroHAWK ID-40 cameras and RS232 interfaces deliver end-to-end pouch and case tracking on the cartoner.

Industry: Tobacco manufacturing
Region: Germany (DACH)
Role: Automation engineer (retrofit)

Focus

•Serialised traceability from pouch to master case using Siemens S7-315 function blocks
•Seamless integration with delta robot, FCC track & trace and labeller systems

Impact

•Batches remain fully traceable – every pouch position is stored
•Quality deviations are rejected automatically and documented for audits

Technologies

Siemens S7-315MicroHAWK ID-40 camerasBosch Rexroth delta robotRS232 & ProfiBus

Open case

11/2022 – 07/2023

Foreign material control in PloomS line

Poland (EMEA): Siemens S7-1511F, TOMRA Helius sorter and string remover ensure foreign material detection with cross-line ProfiSafe communication.

Industry: Tobacco manufacturing
Region: Poland (EMEA)
Role: Automation engineer (integration)

Focus

•Mechanical, electrical and software integration of string remover and TOMRA sorter into the existing line
•Cross-line safety design with ProfiSafe emergency stop coupling and recipe release

Impact

•Foreign material and strings are detected and rejected reliably – product safety increases measurably
•Product quality stays stable, even with recipe changes and parallel line starts

Technologies

Siemens S7-1511FTIA Portal V15.1TOMRA Helius sorterProfiNet / ProfiSafe

Open case

04/2023 – 2024

AGV-supported hall transfer

Germany (DACH): ek robotics AGVs, Siemens S7-414F controls and WinCC link hall 8 and hall 2, including buffer conveyors, barcode validation and shuttle integration.

Industry: Tobacco manufacturing
Region: Germany (DACH)
Role: Lead automation engineer

Focus

•Integrated AGVs with priority-driven FIFO logic into Siemens S7-414F/317F controls
•Enabled end-to-end material tracking and barcode validation between warehouse, buffers and three production lines

Impact

•Material flow between halls 8 and 2 is decoupled and transparent – no manual transports required
•Line supply stays stable during mixed operation, maintenance and shift changes

Technologies

Siemens S7-414F / 317FWinCC supervisory systemek robotics AGVWarehouse control interface

Open case

08/2021 – 03/2022

Maker feeding & DIET integration

Ukraine (CEE): Seven new mini silos, DIET interface and mobile container handling connected via Siemens S7-317F failsafe and WinCC flexible diagnostics.

Industry: Tobacco manufacturing
Region: Ukraine (CEE)
Role: Automation engineer (system integration)

Focus

•Extended container handling with mobile tippers, mini silos and bypass solutions
•Integrated DIET loading and discharge into existing Siemens S7-317F controls

Impact

•Maker lines are supplied flexibly based on demand – buffers and DIET system operate in sync
•Production and maintenance teams keep full transparency of material flow, batch and recipe data

Technologies

Siemens S7-317FWinCC flexibleSINAMICS & SEW drivesS7 communication via Ethernet

Open case

09/2022 – 07/2024

Addback Line Poland: Greenfield & Process Optimization

2-phase automation project: Greenfield installation of a complete addback line with subsequent mini silo integration for process optimization in the tobacco industry.

Industry: Tobacco Industry
Region: Poland
Role: Lead Automation Engineer

Focus

•Batch management with automatic recipe management and barcode validation at entry point
•Weighing belt control (200-2000 kg/h) with grade-dependent flow control (A-F)
•PN/PN coupler synchronization for dosing release and material flow coordination with main line
•Automated process: Barcode check → Tipper → Mini silo → Doffer pre-loosening → Loosening → Weighing belt → Dosing
•ProfiSafe safety engineering (5 circuits) and WinCC process visualization

Impact

•Complex safety programming according to ISO 13849 with 5 safety circuits
•Flexible recipe management with SCADA integration for different product variants
•Optimized material flow through intelligent doffer control (200-2000 kg/h)
•International project experience with complete on-site commissioning

Technologies

Siemens TIA Portal V15.1S7-1516F FailsafeProfiSafe / ProfiNetWinCC 7.4 SCADADanfoss VLT Frequency ConvertersSICK MLG-2 Safety Light CurtainSICK CDF600 Handheld ScannerRAMSEY FLEX Weighing Belt

Open case

02/2025 – 06/2025

Fully automated KUKA palletising cells for building materials

Two fully automated KUKA palletising cells for US building materials manufacturer with pallet magazine, conveyor technology, press table, paper applicator and automated handover to transfer carriage. Complete process from pallet supply to outbound.

Industry: Building materials
Region: USA (Midwest)
Role: Lead Automation Engineer

Focus

•Fully automated process per cell: pallet magazine with singulation → conveyor technology with centring → press table (lift + 90° rotation) → KUKA palletising (faster than press) → paper applicator with intelligent singulation logic → automated handover
•2x identical automation solutions: Each cell with own PLC (TIA Portal V19), 4 positioning axes (press table + paper applicator) and 5 interface technologies (S7, ProfiNet, ProfiSafe, pneumatics, hard-wired I/O)

Impact

•Full automation from pallet supply to outbound: pallet magazine, conveyor technology, press table, KUKA palletising (faster than press), paper applicator and transfer carriage operate without manual intervention
•Intelligent paper singulation (vacuum sensor, error handling) ensures layer-accurate palletising – interlayers are reliably picked individually and placed between product layers

Technologies

TIA Portal V19 (2x identical)8x SEW Movi-C motion controlKUKA palletisersProfiNet / ProfiSafeIntelligent singulation logic

Open case

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