Case

Client: A major food packaging manufacturer in Eastern China (anonymous per client request)

Industry: Food Packaging

Project Timeline: Q2 2025

The Challenge: Poor Compatibility, Frequent Downtime, High Maintenance Costs

A critical packaging line relied on a mix of outdated, multi-brand, non-standard automated equipment. The complex control system, comprising PLCs and relay logic from various manufacturers, led to significant issues:

• Poor System Compatibility: Lack of seamless communication between devices made unified data monitoring impossible.
• Frequent Unplanned Downtime: Electrical system failures caused over 15 hours of monthly downtime on average, severely impacting order fulfillment.
• High Maintenance Costs: Troubleshooting was difficult, spare parts were non-standardized, and reliance on slow, expensive OEM support drove up costs.
• Production Bottlenecks: Overall Equipment Effectiveness (OEE) was consistently below 70%, failing to meet growing market demand.

Xiamen Shun Ding Rui Solution: An Integrated, Compatibility-Focused Retrofit Based on the Siemens Platform

After an in-depth on-site assessment, our engineering team designed a cost-optimal “Core Control Upgrade, Peripheral IO Retention” strategy. This approach maximized performance gains with minimal modifications.

1. Core Control Layer Upgrade:
   • A Siemens S7-1500 series high-performance PLC was installed as the new main control system, providing robust processing power, reliability, and a foundation for future digital expansion.
2. Peripheral Device Integration:
   • We deployed our self-developed “Shun Ding Rui Pro” series of distributed remote I/O modules, which feature seamless compatibility with the Siemens PROFINET communication protocol.
   • These modules successfully integrated three sets of legacy equipment from different brands (including a feeder, sealing machine, and palletizer) into the new Siemens control system, eliminating the need to replace numerous field sensors and actuators.
3. Human-Machine Interface (HMI) Optimization:
   • A Siemens Comfort Panel HMI was configured with an intuitive, unified monitoring interface, allowing operators to oversee the entire production line from a single screen.
4. Professional Technical Services:
   • We provided end-to-end services, including solution design, hardware configuration, programming, commissioning, and on-site technical training, ensuring smooth project implementation.

Quantifiable Results & Value Delivered

Post-upgrade, the packaging line was revitalized, showing dramatic improvements in key performance indicators:

• Dramatically Enhanced Stability: Average monthly unplanned downtime was reduced from over 15 hours to less than 2 hours, an 87% decrease.
• Significant Efficiency Gain: Overall Equipment Effectiveness (OEE) jumped from 68% to 88%, unlocking significant production capacity.
• Reduced Maintenance Costs: Standardized spare parts and simplified maintenance procedures are projected to save the client over RMB 200,000 annually in maintenance and parts costs.
• Visualized Management: Real-time production data collection and monitoring provided crucial data support for management decision-making.

Client Testimonial:

— Mr. Wang, Equipment Department Manager, The Packaging Manufacturer

“The team at Xiamen Shun Ding Rui demonstrated exceptional professionalism. Their ‘Siemens Core + Compatible Modules’ solution precisely addressed our pain points, resolving our long-standing compatibility issues while strictly adhering to our budget. Their products are stable, and their service response is rapid. They have proven to be a trustworthy long-term partner.”