Enterprise Warehouse Management System and Packaging Line Labeling Modernization

Enterprise Warehouse Management System and Packaging Line Labeling Modernization

Industry: Consumer Packaged Goods
Project Type: Manufacturing Systems | Warehouse Management Systems (WMS) | Controls Engineering | Automation | Packaging | PLC/HMI

Project Overview

A large consumer packaged goods manufacturer implemented a new Warehouse Management System (WMS) across four manufacturing facilities to replace its legacy platform. As part of the initiative, the company sought to standardize packaging floor labeling by replacing multiple PLC- and software-based labeling solutions with a single, consistent methodology for product identification and verification.

Matrix Technologies partnered with the client to develop and implement a standardized labeling solution that seamlessly integrated the new WMS with pallet, case, bottle, and sleeve labeling systems across all four facilities.

Scope of Work

Matrix Technologies completed a pre-engineering assessment to document existing packaging floor labeling systems, define future-state requirements, and develop interface protocols between the new WMS and production-line labeling equipment.

Matrix designed and implemented new PLC-based control systems and network infrastructure to communicate labeling data from the WMS to each production line. The project included integration with both new and existing labeling equipment, including printers, applicators, barcode readers, photo eyes, and label verification systems.

To improve flexibility and reduce changeover time, Matrix developed a standardized mobile cart solution that housed all labeling equipment and sensors. The custom carts allowed operators to quickly adjust labeling systems for varying product sizes and container shapes while enabling equipment to be easily transferred between production lines. Each cart was designed, fabricated, assembled, and tested prior to installation.

Matrix provided complete project delivery, including mechanical and controls engineering, fabrication oversight, procurement, installation management, commissioning, startup, and project management across all four manufacturing facilities.

Project Results

The completed project delivered a standardized packaging floor labeling solution integrated with the client's new Warehouse Management System across four facilities.

The new control architecture improved communication between production lines and the WMS, standardized labeling processes, increased equipment flexibility, and simplified product changeovers through the use of interchangeable mobile labeling carts. By providing engineering, integration, installation, and startup services, Matrix Technologies helped the client establish a scalable labeling platform capable of supporting future manufacturing and distribution requirements.