INVT TS600 PLC & DA180 Servo Solution for Overlap Shrink Wrap Machine in India

Abstract: Facing synchronization challenges in overlap shrink wrap packaging, an Indian machinery manufacturer implemented INVT TS600 PLC and DA180 servo solution with EtherCAT and E-Cam functions, achieving enhanced speed, precision, and operational efficiency while successfully replacing a previous controller-based system.

Keywords: DA180 Servo, Packaging, Filling, TS600 PLC, EtherCAT, E-Cam, INVT, HMI, VS-Q, Motion Controller

Brief Introduction
The customer is an Indian company based in Navi Mumbai, Maharashtra, specializing in manufacturing a variety of packaging and labeling machines for industries including food and beverage, pharmaceuticals, and cosmetics.

Customer Requirements
The customer required an easy-to-use, high-efficiency, high-precision, fully automated overlap shrink wrap machine. Their specific needs included:

• Accurate bottle feeding and arrangement

• Properly aligned film overlap and sealing

• Smooth shrink wrapping in the heat tunnel

• Fully automated operation to reduce manual handling

• Easy system monitoring and maintenance

INVT Solution
INVT provided a high-performance solution using TS600 PLC, DA180 servo, and flexible VS-Q HMI to meet the customer’s requirement for a high-precision, high-efficiency, fully automated overlap shrink wrap machine. The system integrates advanced control technologies, including PLC, HMI, and automated synchronization, to ensure reliable, accurate, and fast operation.

Water-filled bottles are fed into the machine individually or in pre-set multi-bottle configurations (e.g., 6, 12, 24) via an infeed conveyor driven by VFD and pneumatic cylinders. Bottles are then transferred to the overlapping conveyor, where the film dispensing and overlapping are precisely synchronized with bottle movement. Finally, the wrapped bundles pass through the heat tunnel for uniform shrink.

Solution Advantages:

• High-speed calculation, which helps to get less scan time

• Supports EtherCAT motion communication to control DA180 servo with high precision. Based on the bottle carrier conveyor, the bottle carrier bar is in synchronized motion, so any drop/increase in speed cannot affect the bottle feeding operation

• Advanced motion control functions for synchronization control, such as electronic cam so that the film overlap on the carrier conveyor is in synchronized motion—any drop/increase in speed cannot affect the bottle film overlap operation

• Bottle feeding / matrix formation can depend on encoder pulse feedback as per user requirements

• No bottle, no feeding of film and cutting of film

Solution Topology:

System Commissioning

Control Panels

Solution Value

1. Synchronized motion control – TS600 PLC with inbuilt 4 cam tables and E-Cam function ensures precise carrier, overlapping, and film feeding movements, delivering consistent packaging quality.

2. Fast and reliable communication – DA180 servo with EtherCAT reduces wiring complexity, speeds up synchronization, and allows real-time cam curve updates.

3. Low maintenance and high accuracy – Electronic cam function minimizes manual adjustment and ensures stable operation.

4. Fully automated operation – From infeed to outfeed, the system reduces human intervention and errors.

5. Customizable functions – Supports production data logic, batch logging, and recipe selection for flexible operation.

Conclusion
Before the upgrade, the overlap shrink wrap machine used another make of motion controller with pulse control and servo, which limited speed, synchronization, and overall efficiency. INVT upgraded the system with TS600 PLC and DA180 servo on EtherCAT, integrating advanced motion control for precise, synchronized bottle feeding, film overlapping, and shrink wrapping. This upgrade significantly improved machine performance, enhancing speed, packaging quality, and operational efficiency. The customer is now highly satisfied with the machine’s performance, experiencing more reliable, automated, and easy-to-maintain operations.