Heat Shrink Packaging Machine

Problem

Manual heat-shrink wrapping is slow and inconsistent: cycle timing that depends on an operator’s judgment produces uneven seals and wasted film. The goal was to automate the wrap-seal-shrink cycle with a PLC so timing and sequencing are repeatable regardless of who’s running the line.

Approach

• Mapped the mechanical cycle (feed, seal, shrink, eject) to a PLC ladder logic sequence, with sensor interlocks so a stage can’t start until the previous one has physically completed.
• Selected and wired the sensors and actuators needed to make each stage detectable rather than time-based where possible, reducing sensitivity to material variation.

Full write-up and diagrams are in the linked document below.

What I’d improve next

• Add a simple HMI for cycle-time and fault monitoring instead of relying on PLC status lights.