Consumer Packaged Goods · Home & Personal Care

Packaging Line Throughput

Add 2.7M units per month by sustaining maximum safe wrapper speed and eliminating film splice events.

74% → 88%

OEE Improvement

Wrapper OEE lifted 14 points (+20% line speed sustained) over the 12-week pilot, with 2.7M additional packages per month on the line

−57%

Film Waste Reduction

Proactive splice scheduling and tension management reduced film waste from 4.2 to 1.8 splices per shift

−73%

Unplanned Stops

SEW drive current signature analysis predicted jaw bearing wear on 3 events before failure

How Allie Works Here

From signal to action in real time.

Production OptimizationPredictive Maintenance

The Production Optimization agent monitors wrapper speed and vision reject rate simultaneously, detecting the inverse correlation between aggressive speed increases and seal quality degradation. It holds speed at the highest sustainable point where the reject rate stays below 0.9% rather than simply maximizing the setpoint. The Predictive Maintenance agent analyzes SEW servo drive current signatures at the jaw axis and film feed axis, detecting bearing wear, eccentricity, and backlash 6–12 hours before the mechanical failure that would cause an unplanned stop. It pre-schedules maintenance tasks in the CMMS during the next planned PM window.

Machines & Connectivity

OT-connected, protocol-native.

Coesia IMA Ilapak Delta 3 Flow Wrapper

Coesia Group

OPC-UA

Primary horizontal flow-wrapper for flexible pouches; speed and sealing are the throughput constraints

Sick Inspector P620 Vision System

Sick AG

EtherNet/IP

Inline print and seal quality inspection; reject gate controlled by vision pass/fail signal

SEW-Eurodrive MOVI-C Drive Controller

SEW-Eurodrive

EtherNet/IP

Servo drive controller for film feed, seal pressure, and infeed timing axes

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Wrapper Speed	`WRAP01.SPD.PPM`	pkg/min	280–340	330–340	Higher
Seal Bar Temperature Deviation	`WRAP01.SEAL.DEV`	°C	±9	±2	Tighter
Film Splice Events per Shift	`WRAP01.SPLIC.CNT`	splices/shift	4.2	1.8	Lower
Vision Reject Rate	`WRAP01.VIS.REJ`	%	1.8–3.4	0.4–0.9	Lower

Wrapper SpeedHigher

WRAP01.SPD.PPM

Baseline: 280–340 pkg/min→ 330–340 pkg/min

Seal Bar Temperature DeviationTighter

WRAP01.SEAL.DEV

Baseline: ±9 °C→ ±2 °C

Film Splice Events per ShiftLower

WRAP01.SPLIC.CNT

Baseline: 4.2 splices/shift→ 1.8 splices/shift

Vision Reject RateLower

WRAP01.VIS.REJ

Baseline: 1.8–3.4 %→ 0.4–0.9 %

In the Field

"a multi-category food group operating 14+ filling and packaging lines across two plants, pilot deployed on the highest-volume flow-wrapper SKU first, then replicated across the line cluster"

Deployed at a multi-category food group operating 14+ filling and packaging lines across two plants, pilot deployed on the highest-volume flow-wrapper SKU first, then replicated across the line cluster. The results above reflect production data from the 60–90 day period following full deployment.

74% → 88%oee improvement

−57%film waste reduction

−73%unplanned stops

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

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