Customer Story: Track & Trace at Meguin

“We could not produce these quantities any other way.”

Christian Texter – Plant Manager Meguin Mineral oil plants

Transparency is of the utmost importance at Meguin. All information about the product is contained in the unique code on the lid:

• Batch
• Container
• Labels
• Production date and time
• Weight and other quality data

This information makes each individual container and its contents traceable. Meguin even takes further steps to track products through the supply chain: the TQS-CP aggregates the individual packaging unit with the carton, which is then associated with the specific pallet. This makes it possible to trace where each unit has been delivered to. If a unit is identified more than once or if it is identified in the wrong place, the anti-counterfeiting alarm goes off.

To comply with the packaging regulations, Meguin uses checkweighers in all lines. As Christian Texter recalls: “Checkweighers were the first step in making our production quantifiable.” The measurements were saved and managed in production processes. The start and end of a production assignment were thus clearly defined and comparisons between target and actual values were possible. The communication between checkweighers and MES forms the basis for this. As Texter states, open interfaces and standardized data exchange using the OPC UA protocol offer significant advantages: “Wipotec has made the process both convenient and simple – very modern.” This is why Wipotec systems from the TQS series with fully integrated cameras are now also in use in automated lines. Their system character proves its value because containers do not have to be tracked throughout the process to reliably assign the weight to a specific code. And the more functions a TQS unit combines in its central control system, the more advantages it has. The semi-automatic line for small batches at Meguin clearly demonstrates that.

Meguin categorizes its product range in production according to batch size. In categories A and B, the quantities are larger and are produced, filled and packaged in fully automated lines. While these products account for 80 % of sales, the remaining 20 % require more effort: there are around 2,000 different articles in category C, which are produced in small batches. Christian Texter and his team optimize and improve efficiency wherever possible: “Running small batches on a separate line frees up capacity and speeds up large-scale production.” However, the space for an additional line is limited and expanding the area is not an option. The growing focus on automation is additionally raising performance standards: “I could never understand that all components have to be controlled individually. This is far too error-prone and extremely complex due to the many interfaces,” Texter states when talking about his search for a centrally controlled solution. He adds: “Wipotec then came up with the idea of integrating weighing, scanning, labeling, printing and cameras for quality control into a single system.”

The development proves its worth: “The system is very reliable. All product parameters are automatically loaded from the MES at the start of production," Texter notes with satisfaction and praises the Wipotec service: “Communication during commissioning was excellent. A lot of know-how is needed, especially when it comes to camera technology. When we have any inquiries, we receive quick and solution-focused assistance. We are very pleased with the results.” 

• Compact design
• All modules under a single control unit
• Standardized data exchange using OPC UA
• Printing color changes are quick and easy
• Easy changeover between round and square containers
• Quick and reproducible article changes
• One contact for service and support
• Minimized training effort
• No teach-in and reconfiguration required

The results of small-batch production speak for themselves – which is why Christian Texter is in favor of expanding the collaboration: “This is the philosophy of the future and we can see these systems on our high-volume lines too.”

“This flexibility greatly simplifies our production.”

Christian Texter – Plant Manager Meguin Mineraloelwerke

Meguin has switched from marking their products with a Data Matrix in UV ink to a visible QR code. This code combines variable production data with a web link. End consumers can also scan the code with their smartphones – which creates completely new possibilities for counterfeit protection, traceability and marketing.