A hopper drive system that was previously running direct-on-line with abrupt starts and stops was upgraded to variable speed drive control with independent brake logic and PLC changes. The result was smoother operation, reduced mechanical shock, improved control, and a more refined machine sequence.

Real-time label printing system deployed across 30 roll-forming machines using Node-RED. The system reads order data from the PLC (via RS485 legacy integration) and triggers label printing on every shear event—ensuring accurate, automated product identification with zero manual input.

Upgraded a standalone Chinese pallet wrapper into a fully integrated accumulation system—reducing stoppages, improving pallet flow, and increasing overall line efficiency through structured PLC control.

Restoration and integration of an existing pallet wrapper into a palletiser cell, improving safety, reliability, and operator usability through practical automation and control upgrades.