MDSC-900E Metal Double Sheet Detector | Leisure Food Bag Feeding Machine Anti Double Bag and Multi Bag Feeding Ground Application Case

1、 Overview

The fully automatic bag packaging production line for leisure food is prone to problems such as bag adhesion and overlapping feeding of double/multiple bags during high-speed bag picking operations, which can lead to equipment jamming, shutdown, material waste, poor packaging, and other malfunctions, affecting the production capacity and product quality of the production line. In response to the common pain points in this industry, the AtonmMDSC-900E metal double detector is deployed on site, pre installed between the bag feeding machine and the bag opening and filling process. The equipment relies on high-precision electromagnetic induction detection principle to automatically identify the status of single bags and stacked bags, and intercept abnormal feeding in real time. The solution does not require the modification of the original production line, is easy to install and debug, and adapts to high-speed production rhythms. It can effectively stabilize the operation of the production line, reduce production losses, and improve the packaging yield rate. It is a lightweight and highly stable bag stacking detection solution for food packaging production lines.

2、 Project Background

This customer is a leading domestic leisure food production enterprise with multiple fully automatic bag feeding packaging production lines, mainly used for automated filling and sealing operations of braised and dried fruit products. The production line has a high degree of automation, fast production pace, and continuous mass production throughout the year.

The original production line did not have a pre stack bag detection function, and when the equipment picks up bags at high speed, thin metal composite film bags are prone to sticking and stacking. Once double or multiple bags enter the filling station, it will directly cause problems such as bag opening failure, filling misalignment, poor sealing, and material leakage. This not only wastes packaging materials and food raw materials, but also leads to equipment jamming and frequent production interruptions, increasing rework and quality inspection costs, and severely restricting production line efficiency and product stability.

To solve the problem of bag stacking and feeding from the source, reduce production failures, and improve costs and quality, the customer has introduced the AtonmMDSC-900E metal double detector, which is deployed in front of the bag feeding and discharging station to achieve accurate detection and abnormal interception of bag quantity.

3、 On site working conditions and core pain points

1. On site working conditions

The on-site is a high-speed fully automatic bag packaging production line, which operates continuously throughout the year without interruption. It has strict requirements for the response speed and operational stability of the testing equipment. There is slight dust and equipment vibration in the production environment, and the installation space of the equipment is compact. It is required that the detection equipment be small in size, easy to install, and do not require complex debugging. The packaging bags on the production line are made of metal composite film material, fully compatible with the principle of metal induction detection.

2. Core pain points

• Strong limitations of manual detection: High speed production lines rely on manual labor to identify fine adhesive bags in real time, resulting in a high rate of missed detections and inability to avoid bag stacking and feeding problems from the source.

High production losses: Stacking bags and feeding materials can easily cause filling and sealing failures, resulting in a large amount of waste and continuously increasing production costs.

Frequent downtime on the production line: The bag stacking machine is prone to equipment failure and requires manual cleaning and restart, occupying effective production time and restricting capacity release.

• Unstable product quality: Some hidden stacking bags can cause air leakage and poor sealing, leading to quality hazards and after-sales risks.

4、 Solution and device deployment details

Based on the on-site production line rhythm, packaging materials, and continuous mass production requirements, the customer has selected the AtonmMDSC-900E metal double sheet detector. With mature electromagnetic induction detection technology, it is adapted to high-speed automated production lines and accurately solves the problem of bag stacking and feeding for bag feeding machines.

1. Equipment core adaptation advantages

MDSC-900E is specially developed for the detection of overlapping thin sheets and bags, and is suitable for metal composite film bag detection conditions. The equipment has high detection accuracy and fast response speed, and can adapt to a production cycle of up to 600pcs/min. It fully matches the high-speed operation requirements of the production line, without detection delay or jamming. The equipment is equipped with optimized signal algorithms and shockproof and electromagnetic shielding structures, which can resist on-site dust and equipment vibration interference, and have strong continuous operation stability.

The device can accurately distinguish between single, double, and multiple overlapping film bags, effectively avoiding false positives and omissions. The whole machine is compact in size, easy to connect, supports dual signal output of NPN/PNP, and can be directly connected to the original production line PLC system without the need to modify the original equipment. Installation and debugging are fast, and it can be quickly adapted to mass production.

2. On site deployment and operational logic

The equipment probe is accurately installed at the key pre production stations of the bag feeding machine for discharging, opening and filling. It conducts full coverage testing on all incoming packaging bags and automatically determines the number of bags through metal induction signal differences. It is linked to the production line to achieve automated control:

Detected a single normal bag body: output a release signal, and the production line completes the bag feeding, opening, and filling processes normally;

Detected double bag/multiple bag overlap abnormality: immediately output interception signal, trigger instantaneous shutdown through PLC control system linkage, and activate sound and light alarm to remind on-site operators to clean the abnormal bag body. After troubleshooting, the production line will automatically resume operation.

The entire testing process is fully automated and operates in a closed-loop manner, without the need for manual intervention. It blocks bag stacking from entering the core process at the source, effectively avoiding various production abnormalities in the future.

5、 Implementation effect

After the equipment was put into mass production, it operated stably for a long time, effectively solving the problem of double bag and multi bag feeding in the bag feeding machine, effectively improving the stability of the production line and packaging yield, and achieving significant results in cost reduction and efficiency improvement.

1. Effectively avoid abnormal feeding of stacked bags

Realize 100% accurate identification and interception of stacked bags, effectively avoiding double or multiple bags from entering the filling station, solving problems such as machine jamming, filling failure, and poor sealing from the root, and eliminating hidden quality hazards in core packaging.

2. Significantly reduce production losses and labor costs

Significantly reduce material and packaging waste caused by stacking bags, and significantly reduce the generation of defective waste products. At the same time, it reduces the cost of equipment failure cleaning, rework of defective products, and manual inspection, effectively controlling the operation and maintenance expenses of the production line.

3. Stabilize the production line rhythm and improve overall production capacity

Effectively solving the problem of sudden shutdown, ensuring 24-hour continuous and stable production on the production line, significantly increasing the effective production time, effectively eliminating the constraints of bag stacking failures on production capacity, and significantly improving overall production efficiency.

4. Suitable for long-term mass production, stable and reliable operation

The equipment is suitable for complex working conditions in food workshops, with excellent resistance to dust, vibration, and interference. It can operate continuously for a long time without data drift or faults, and does not require frequent calibration and maintenance. It is suitable for high-intensity mass production needs.

6、 Case Summary

Stacking bags is a common challenge in the automated packaging production line for leisure food, which directly affects production capacity, yield rate, and production costs. The AtonmMDSC-900E metal dual detector, with its advantages of precise detection, fast response, strong stability, and easy installation, is perfectly adapted to the working conditions of high-speed food packaging production lines and efficiently solves the pain points of bag stacking and feeding.

This renovation plan has low cost, fast implementation, and intuitive effect, without the need to modify the original production line structure. It can quickly achieve multiple values of improving quality, reducing costs, and increasing efficiency. It can provide mature and replicable bag stacking detection solutions for various fully automatic bag feeding food packaging production lines.