Integrating legacy equipment into data networks is simpler and more affordable than most manufacturers believe, requiring only low-cost sensors and basic PLCs to capture essential data points and enable gradual digital upgrades.
- Most packaging machinery is easier and cheaper to upgrade than commonly perceived by industry professionals
- Start with basic data points like speed, status, and output using low-cost sensors and entry-level PLCs to establish connectivity
- Flexible data systems can handle diverse protocols from various equipment types without major overhauls
- Employee engagement and clear demonstrations of actionable insights drive cultural acceptance of data collection initiatives
- Gradual modernization allows manufacturers to work their way up from basic monitoring to advanced data utilization
Packagers and processors see the difficulty of integrating legacy equipment into data connectivity networks and data capture processes as a major barrier to achieving standardization of acquired data and its scalability. However, there are solutions to ease this burden.
That’s according to PMMI Business Intelligence’s “Data Acquisition, Sharing and Utilization,” a report that captures insight from packaging and processing end-users and OEMs on obstacles and benefits of integrating growing levels of digital connectivity and data utilization into manufacturing operations for operational efficiency. The report stems from a Q&A session and roundtable discussions between expert panelists and industry participants at PACK EXPO International 2024.
Solutions to the integration barrier
A key discussion theme was the need to simplify data capture while ensuring the accuracy of data. Recommendations included installing low-cost sensors and maintaining flexibility in data systems to handle diverse protocols from various equipment types.
Moreover, fostering a culture shift by engaging employees and providing clear demonstrations on why data is being collected through actionable insights was emphasized.
Integrating legacy machinery into digital networks was identified as an obstacle to effective use of data. Yet, professionals noted that most packaging machinery is much easier and cheaper to upgrade than it is often perceived to be.
“I would say that if you are dealing with equipment that doesn’t have any connectivity, you can, again, start off with the basic data points (speed, status, output). Get some sensors and a low-end PLC (Programmable Logic Controller) that doesn’t cost you a lot of money to get your foot in the door… and then you can work your way up from there. There’s nothing that prevents you from instrumenting an older machine with more modern PLCs for data capture,” said one industry professional.
SOURCE: PMMI Business Intelligence: Data Acquisition, Sharing and Utilization
For more insights from PMMI’s Business Intelligence team, find reports, including “2024 Technology & Workforce: Using Smart Technologies to Bridge the Skills Gap” and “2024 Contract Packaging & Manufacturing: Drivers of Machinery Investments” at pmmi.org/business-intelligence.
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