Pallet Wrapper Restoration & Integration
Keep Production Moving with Practical Automation Upgrades
When this pallet wrapper project came in, the goal was straightforward: restore reliable operation, integrate the wrapper into the palletiser cell, improve safety integration, and make the machine simple for operators to use again.
Like many brownfield machine projects, the wrapper was not a clean slate. It needed fault finding, control system improvements, safety integration, mechanical coordination, and practical operator-focused commissioning — all without overcomplicating the machine.
Peak Control delivered a complete restoration and integration outcome that brought the wrapper back into service and left the client with a system that was safer, easier to run, and ready for ongoing production.
The Challenge
This project involved an existing pallet wrapper being integrated into a live palletiser cell. The machine needed to work reliably with the upstream equipment while also meeting practical safety and operational requirements.
The key challenges included:
Restoring reliable wrapper operation
Integrating the wrapper into the existing palletiser cell and sequence
Improving safety logic and field device coordination
Reducing operator confusion with simple, usable controls
Managing on-site realities, including undocumented differences and small mechanical/electrical issues that appeared during commissioning
This was not just a programming task. It required hands-on electrical, automation, safety, and commissioning support to get the full system working properly.
Our Approach
Peak Control carried out a staged restoration and integration process, including:
1. Fault Finding & Restoration
We diagnosed the wrapper system, identified failed and problematic components, and worked through the control and field issues preventing reliable operation.
2. Control System Integration
The wrapper was integrated into the main palletiser cell so it could operate as part of the broader production flow, rather than as a standalone machine. This included refining run conditions, discharge logic, and interlocks between machines.
3. Safety Improvements
Safety functions were reviewed and updated as part of the integration, including light curtain and muting-related logic, machine run-state dependencies, and safer system behaviour during normal operation and intervention.
4. Operator-Focused Logic Improvements
The system was tuned to make operation straightforward for production staff. Manual functions, pallet handling behaviour, and sequence logic were adjusted to improve usability without adding unnecessary complexity.
5. Documentation, Validation & Handover
The completed system was supported with updated documentation, operating guidance, training, and a formal handover package so the client had a clearer path for operation and ongoing maintenance.
Scope Delivered
The pallet wrapper project included work across multiple disciplines:
Electrical fault finding and control troubleshooting
PLC and sequence modifications
Wrapper-to-palletiser cell integration
Safety logic updates and validation support
Field wiring and control adjustments
Operator training and handover
Final operating manual and supporting documentation
This is where Peak Control adds value: not just writing code, but tying together electrical, automation, and operational requirements into one practical outcome.
The Result
The wrapper was restored, integrated, and returned to service with a much simpler operating experience for the client’s team.
At handover, operator training was completed and the feedback was positive — the machine was described as easy to run, with the main point of attention being pallet alignment.
The project left the client with:
A working pallet wrapper back in production
Seamless integration within the palletiser cell and upstream equipment
Safer and more reliable operation
Clearer operating documentation
Greater confidence for operators using the machine day to day
Why This Project Matters
Many automation projects are not greenfield installations. They involve existing machines, mixed documentation quality, real-world production constraints, and the need to get results quickly.
This case study reflects the type of work Peak Control is built for:
restoring underperforming equipment
solving practical automation and electrical problems
improving safety and usability
integrating machines into existing production lines
delivering outcomes that operators can actually live with
Need Help with an Existing Machine or Production Line?
Whether you need to restore a machine, improve a process, integrate new equipment, or make an existing system safer and easier to run, Peak Control can help.
Peak Control delivers hands-on electrical and automation support for machine upgrades, safety improvements, troubleshooting, and long-term production optimisation.
Call to Action
Have a machine or line that needs attention? Get in touch to discuss your project.
Brownfield machine upgrades
Palletising and wrapping systems
PLC and control improvements
Safety integration and validation support
Electrical and automation fault finding
