PLC-Based Automated Sorting System in Smart Packaging Industry

Rabeaa, Mohammed

doi:10.25673/123749

Proceedings of International Conference on Applied Innovation in IT · 2026/03/31 · Vol. 14 · Issue 1 · pp. 1435–1441

PLC-Based Automated Sorting System in Smart Packaging Industry

Mohammed Abdul Jaleel Maktoof and Mustafa Moaied Rabeaa

📄 Download PDF DOI: 10.25673/123749

Abstract

As the packaging industry needs more efficiency, accuracy, and traceability, it needs to use more advanced automation solutions. This study introduces a PLC-based automated sorting system tailored for smart packaging applications, incorporating sensors, pneumatic actuators, conveyors, and a programmable logic controller compliant with IEC 61131-3 standards. The proposed system is further improved with SCADA/HMI interfaces that let operators see data in real time, interact with it, and monitor it. Testing under different conditions, such as conveyor speed, item spacing, sensor standoff, and diverter delay, showed big improvements in performance metrics. The system could classify items with 96.8% accuracy, had an average latency of 122 ms, and could process up to 720 items per hour. Overall Equipment Effectiveness (OEE) was 86.2%, which was better than manual sorting (61.8%) and standard PLC systems (72.5%). Statistical analysis confirmed the resilience of the proposed framework in industrial packaging environments. The study presents a replicable PLC-based methodology that integrates deterministic control, real-time feedback, and secure operator interaction, providing a viable framework for Industry 4.0-compliant smart packaging.

Keywords

Programmable Logic Controller (PLC) Automated Sorting Smart Packaging SCADA OEE Pneumatic Actuators Industry 4.0 Latency Throughput Real-Time Monitoring.

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