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Case Study: Controls Integration for a Packaging Line Retrofit in a Beverage Facility

A Mid-Atlantic beverage manufacturer needed to replace a slow palletizer and improve packaging line performance without disrupting production. Cornerstone Automation provided practical controls integration, on-site support, project management and engineering across the entirety of the project – helping the plant reuse existing PLCs, improve throughput, and simplify reject handling.

Upgrading one machine often means rethinking how the whole line works. In this case, a faster palletizer exposed bottlenecks in an aging packaging system. With limited in-house controls staff, the plant turned to Cornerstone Automation to manage the integration, update multiple PLCs, and guide the system through commissioning with minimal downtime.

Project Overview

A privately owned beverage plant in the Mid-Atlantic region produces a variety of shelf-stable, dairy-based drinks. The facility operates multiple filling lines feeding a single packing line with limited internal engineering resources. Because the plant has limited in-house controls support, it relies on outside partners like Cornerstone for capital upgrades and production improvements.

The Challenge

The packaging system had grown organically over time. Panels were isolated from each other, some had aging controls with no documentation, logic was custom, and machine-to-machine communication was inconsistent. When the plant chose to replace its slow robotic palletizer with a faster conventional unit, the change required a broader line rework involving removing & replacing many of the conveyors, rigging, electrical wiring modifications, fabrication, large panel relocation, more power distribution and short downtime windows.

Without adjustments to conveyors, case handling, and downstream inspection, a conventional palletizer (effectively doubling their max throughput) there simply was no footprint to fit the new requirements into the existing conveyor layout. Existing PLCs and HMIs needed updated logic, and coordination across mechanical and electrical vendors was limited. With no central integration lead, the risk of delays and system mismatches was high.

The Solution

Cornerstone Automation stepped in to lead the controls integration, engineering and project management. We provided hands-on support during installation and commissioning, scope and RFQ generation for subcontractors, scheduling services, onsite panel rebuilds and other project management services. Rather than install new hardware, the team focused on updating and synchronizing the plant’s existing controls infrastructure as much as possible.

PLC & Systems Integration

The project involved six existing Allen-Bradley PLCs and multiple vendors associated with all the equipment involved:

• • Conventional Palletizer (CompactLogix)
  • Robotic Palletizer (CompactLogix)
    
  • Stretch wrapper (MicroLogix 1000)
    
  • Conveyor supervisor (ControlLogix)
    
  • Case erector (CompactLogix)
  • Shrink wrapper (CompactLogix)

Cornerstone reprogrammed each controller to improve system communication and match the performance of the new palletizer.

Conveyor & Line Coordination

• • Integrated existing standalone hytrol conveyors into comprehensive line control
  • Installed additional hytrol zones and setup for proper gapping, speed reference and tied into newly installed safety circuits
  • Programmed Hytrol Aux I/O modules to bridge upstream and downstream systems
    
  • Reworked airlocks and rate matching logic to reduce product backups
    
  • Improved accumulation logic to maintain line balance and smooth flow
  • Provided engineering, scheduling and guidance for mechanical and electrical subcontractors.

Robotic Palletizer Modifications

• Revised electrical schematic and provided detailed electrical diagrams for electrical subcontractors. 
• Reverse engineered pick station and robot controller wiring as well as third party safety circuit so that conveyors could be temporarily run between the multi phases of this project.
• Removed and isolated the components associated with the empty pallet dispenser so the customer could stage components as isolated units for resale.

Stretch Wrapper Modifications

• • Complete reverse engineering of undocumented, obsolete PLC program
  • HMI, PLC and in panel rework to support interconnects to new conventional palletizer and remove old robot interconnects and programming.
  • Supplied drawing revisions, 
  • Reworked photoeyes and motor controls to allow for coordination with new palletizer, temporary operation without any accumulation zones and operation of stretch wrapper from opposite side of existing layout.

Case Erector & Sealer Enhancements

• • Rewired control panels with additional new PowerFlex 525 drives, 750VA encapsulated transformers, and 100S-E safety contactors, along with new, revised electrical schematics and proper short-circuit protection. 
    
  • Added photoeyes, gate sensors, and proximity switches to improve reject detection
    
  • Integrated downstream logic for smoother discharge and higher throughput
    
  • Modified case erector PLC to support new reject logic and feedback
  • Built & Installed panels for wire extensions and provided field drawings for new runs that were required.

• • Reworked both panels to integrate multiple standalone conveyors into centralized control, safety zones and coordinated start/stop
    

Vision System Integration

• • Connected a Cognex In-Sight 2800 series vision system to the case erector PLC
    
  • Installed a new Ethernet switch and 24VDC safety-rated relay
    

• • Verified nozzle detection and coordinated rejection sequence during commissioning
    

Onsite Commissioning & Support

Cornerstone supported the project from planning through post-installation testing, including:

• • Answering field wiring and logic questions across multiple vendor teams
    
  • Supporting panel relocation and conveyor rework
    
  • Making real-time adjustments during rate testing and final signoff

Their on-site involvement kept the startup on schedule and ensured each piece of equipment functioned reliably as part of the overall line.

Results

• Increased throughput: The packaging line now supports higher palletizer speeds without product backups.
  
• Improved quality oversight: The integrated vision system and reject logic provide faster, more reliable quality control.
  
• Reduced downtime and confusion: Updated PLC logic, accurate electrical drawings and clearer panel layouts simplified troubleshooting and support.

Rather than replacing everything, Cornerstone worked with the plant to reuse and optimize existing systems, making only the changes needed to support higher performance and reliability. Their continued involvement throughout the upgrade helped avoid miscommunication, reduce commissioning risk, and minimize unplanned downtime. After commissioning, the plant reported smoother flow, fewer product backups, and simpler troubleshooting during changeovers.

Lessons Learned

This comprehensive line rework highlights the importance of proactive controls coordination, especially when multiple vendors are involved and field commissioning support is needed across evolving OEM equipment.

Key takeaways for similar facilities:

• • Don’t assume new equipment will “drop in” without affecting existing systems
    
  • Older PLCs and panels can be reused with thoughtful programming updates
    
  • Involving controls engineers early prevents miscommunication and post-installation delays
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Following the upgrade, the plant has continued working with Cornerstone for ongoing support and future system changes as production needs evolve.

Interested in Upgrading Your Packaging Line?

Whether you’re dealing with aging controls, new equipment, or unclear vendor scopes, the right integration partner can help you avoid downtime and keep production moving.

Learn more about our Control System Integration Services or Contact Cornerstone Automation to talk through your next project.