Food Packaging Double Package Detection Solution - Atorm MDSC-900E Metal Double Sheet Detector

1、 Project Background and Problem Statement

1.1 Industry Pain Points

In the food packaging automation production line, composite packaging bags containing aluminum foil layers often experience double or even multiple bag overlapping during transportation due to electrostatic adsorption, stacking, or abnormal bag handling. This seemingly minor issue causes sustained losses to the production line:

Direct loss:

• After entering the bag opening station, the suction cup cannot be opened normally, resulting in bag loading failure and material leakage
• Abnormal bags enter the sealing process, causing quality accidents such as weak sealing and air leakage
• Forced shutdown for cleaning and resetting, with a single shutdown affecting the production capacity of tens to hundreds of packages

Hidden losses:

• Operators continue to monitor, resulting in high labor costs
• Relying on experience judgment after shift change, poor consistency in detection
• The problem is located in the later stage, with high processing costs and slow response times

Core contradiction:Traditional photoelectric sensors can only determine "presence" and cannot identify "several". If the double bag problem is not intercepted at the source, it will continue to spread backwards and eventually concentrate on the later workstations.

2、 Solution Overview

2.1 Core of the Plan

This plan is recommended to adoptAtorm MDSC-900E metal dual detectorIn the packaging bag conveying process, single bag/double bag online recognition is achieved, and the detection signal is linked with the production line PLC to achieve automatic removal or shutdown alarm of abnormal bags.

Core principle:MDSC-900E adopts electromagnetic induction detection technology to detect the inside of packaging bagsChanges in the total amount of metal in the aluminum foil layerTo distinguish between single bags and stacked bags. A single bag corresponds to a set of signal windows, and when double or multiple bags are stacked, the total amount of metal layer doubles, and the signal clearly exceeds the window threshold, thus achieving accurate recognition.

2.2 Product selection criteria

3、 Technical solution design

3.1 Installation location

Install the MDSC-900E sensor onThe straight and stable conveyor zone in the middle section of the conveyor beltLocated after the bag sorting section and before the bag opening station.

Key points for location selection:

• Select the section with the most stable bag posture (avoiding turns and vibration sources)
• The sensor transmitter (T) is on top, the receiver (R) is on bottom, and the working surface is installed facing each other
• The recommended working face spacing is 40mm, which can be adjusted between 30-50mm according to the bag thickness
• The detection area needs to be clear and free of other metal obstructions

Why did you choose this location?In the initial stage of bag sorting, the bag posture is unstable, with many folds, random edge sealing positions, and large signal fluctuations. After moving the detection point to a stable straight line area, the bag posture consistency is good and the detection stability is significantly improved.

4、 Core advantages

4.1 Advantages of detection principle

• Non contact detection: Do not touch the bag surface to avoid secondary damage
• Penetration detectionNot affected by bag printing, oil stains, or wrinkles, with high detection stability
• precise identificationDetect changes in the total amount of metal layer, with clear signal differences between single and double bags and low false alarm rate

4.2 Performance parameter advantages

4.3 Engineering adaptation advantages

• Full Metal JacketAnti magnetic and earthquake resistant, suitable for production line vibration environment
• Electromagnetic shielding technologyResist interference from devices such as motors and frequency converters
• One click automatic learningNo need for repeated debugging during changeover, easy to operate
• Seamless integration with PLCStandard switch signal output, supporting NPN/PNP
• Through installationThe sensor is a reflective structure, suitable for online detection of conveyor lines, without the need to damage the existing production line structure

5、 Expected benefits

After deploying MDSC-900E, it can bring the following comprehensive benefits:

• Significantly reduce the inflow of double bags into the rear sectionOnline interception of double bags, no longer passively handling bag stacking anomalies at the later stage workstation, significantly reducing the frequency of downtime, rework, and cleaning
• Reduce consumables and material wasteTo avoid packaging bag loss caused by double bags, as well as content loss caused by problems discovered only after filling
• Protect the equipment in the later stagePrevent double bags from entering sealing devices, suction cups, and other workstations to reduce abnormal wear and mold damage
• Stable production line rhythmThe action of removing double bags is automatically completed in the early stage, making the entire line run more smoothly and not disrupting the production rhythm due to double bag problems
• Improve product quality consistencyReduce quality accidents such as poor sealing and air leakage caused by double bags, and lower the risk of customer complaints
• Reduce manual dependenceThe operator no longer needs to continuously monitor the bag, only needs to handle the alarm point, and the testing standards are consistent after the shift change, without relying on experience judgment
• Easy installation and maintenanceThrough installation does not damage the existing production line structure. When changing different bag types, one click teaching is sufficient without the need to replace hardware

8、 Conclusion

The Atorm MDSC-900E metal double detector uses electromagnetic induction technology to detect changes in the total amount of metal in the aluminum foil layer of packaging bags. It can accurately identify single bags and double bags during the conveying process and complete the detection signal output loop within a few hundred microseconds, intercepting anomalies before the bag opening station.

This solution has the advantages of non-contact detection, strong anti-interference ability, fast response speed, and simple adaptation. It can effectively solve the long-term pain point of double bag stacking in food packaging production lines, help factories reduce consumables waste, reduce downtime losses, and improve the intelligence level of production lines.

Confirmation of applicable prerequisites:The packaging bag must contain a continuous layer of aluminum foil. If this condition is met, MDSC-900E is an excellent solution to the double bag problem