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09/2022 – 07/2024

Addback Line Poland: Greenfield & Process Optimization

International project responsibility for the complete automation of an addback line in the tobacco industry – from greenfield installation to process optimization with mini silo integration. The project comprised two phases over a period of 2 years with full responsibility for engineering, programming, FAT and on-site commissioning.

Project at a glance

Period
09/2022 – 07/2024
Industry
Tobacco Industry
Region
Poland
Role
Lead Automation Engineer

Project Details

Initial situation

  • •Greenfield installation of an addback line with fully automated batch management and recipe-barcode validation
  • •Precise weighing belt control for grade-dependent dosing (A-F, 200-2000 kg/h) synchronized with main line
  • •Later integration of a mini silo with doffer pre-loosening for process optimization without production interruption

Solution

  • •Phase 1 (09/2022-05/2023): Batch management system with recipe management and automatic barcode validation in TIA Portal V15.1
  • •Barcode scanner at entry verifies label data against recipe data – material is released only when data matches
  • •Automated process flow: Material is tipped into mini silo, doffers pre-loosen, loosening device shreds, weighing belt doses
  • •Weighing belt control: Recipe setpoint (200-2000 kg/h) is dosed weight-based until target weight is reached
  • •PN/PN coupler synchronization with main line: Dosing release and grade (A-F) control flow adjustment
  • •Surge bin PID control with 4 photo eyes for level detection and frequency-based belt speed control for constant material flow
  • •Phase 2 (09/2022-07/2024): Mini silo integration (2.4m³, 3 doffers) optimizes pre-loosening and material flow
  • •ProfiSafe safety concept (5 circuits) and WinCC 7.4 SCADA for recipe management and process monitoring

Impact

  • •Fully automated batch management: Load recipe, validate barcode, dose grade-based – without manual intervention
  • •Precise material flow control: Weighing belt regulates 200-2000 kg/h weight-based, synchronized with main line via PN/PN coupler
  • •Process optimization through mini silo: Doffer pre-loosening reduces blockages and improves throughput

Technologies & interfaces

Siemens TIA Portal V15.1 (PLC Engineering)S7-1516F-3PN/DP Failsafe CPUProfiSafe F-DI/F-DO ModulesProfiNet Industrial EthernetWinCC 7.4 SCADA (Windows Server 2016)Siemens TP1500 Comfort PanelDanfoss VLT Frequency ConvertersSICK MLG-2 Safety Light Curtain with MutingSICK CDF600 Barcode ScannerRAMSEY FLEX Weighing BeltPID Controller for Surge Bin Level

Project FAQs

What was Prybisch Automation's responsibility?
Lead Automation Engineer. Phase 1 (09/2022-05/2023): Batch management system with recipe management and automatic barcode validation in TIA Portal V15.1
Which technologies were integrated?
Siemens TIA Portal V15.1 (PLC Engineering), S7-1516F-3PN/DP Failsafe CPU, ProfiSafe F-DI/F-DO Modules, ProfiNet Industrial Ethernet, WinCC 7.4 SCADA (Windows Server 2016), Siemens TP1500 Comfort Panel, Danfoss VLT Frequency Converters, SICK MLG-2 Safety Light Curtain with Muting, SICK CDF600 Barcode Scanner, RAMSEY FLEX Weighing Belt, PID Controller for Surge Bin Level.
Where was the project delivered?
Poland.

Client takeaway

This 2-phase project demonstrates my expertise in complex automation projects – from greenfield installation to continuous process optimization. With comprehensive responsibility for engineering, safety programming and on-site commissioning.

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