A large North American dairy manufacturer needed a more reliable way to manage pallet labeling, tracking, barcode verification, and ERP communication across its packaging operations.
The facility had outgrown a mix of custom-developed applications, vendor tools, and manual data handling steps used to create pallets, print labels, and keep production information aligned with the ERP. As packaging requirements changed, the existing approach became harder to maintain and more difficult to extend across additional lines and processing areas.
Cybertrol Engineering implemented PalletWorks®, its configurable production labeling software platform, to manage end-of-line pallet activity, automate label generation, verify barcode data, and synchronize validated production information with the customer’s Data Specialists, Inc. ERP environment.
Industry: Dairy manufacturing
Application: Packaging automation, pallet labeling, and ERP integration
Software: PalletWorks® production labeling software
Operator Interface: Rockwell Automation FactoryTalk® Optix
Integration: DSI ERP API integration, PLC communication, barcode verification, label printing, and offline data handling
The customer’s packaging environment had developed over time into several separate applications responsible for pallet creation, label printing, production data management, and ERP updates. These tools were functional, but they required manual intervention and custom workarounds to keep pallet information accurate as product moved through production and downstream processing.
Communication delays or data mismatches could create operational interruptions, require manual corrections, and make it harder to maintain accurate finished goods information. The customer also needed a better foundation for future packaging enhancements without continuing to rely on custom code for each new requirement.
The project needed to address several operating priorities:
Improve communication between packaging equipment and the ERP
Reduce manual handling of pallet and label data
Maintain accurate information throughout the pallet lifecycle
Support barcode verification before pallets moved downstream
Provide operators with better tools for production order selection and pallet management
Replace custom-developed applications with configurable manufacturing software
Cybertrol began by defining the required operating sequences, operator interactions, exception handling, PLC communication, and ERP data exchange. This functional design work established how PalletWorks would manage pallet activity from creation through label verification and ERP synchronization.
Cybertrol implemented PalletWorks to support the customer’s end-of-line packaging requirements, connecting plant-floor pallet activity with ERP data exchange through defined software, PLC, and API integrations.
FactoryTalk Optix operator interfaces were also developed for use on industrial tablets and operator stations. These screens gave authorized users a consistent way to select production orders, scan labels, manage pallet information, and handle defined exceptions from the plant floor.
PalletWorks was implemented as the central application for pallet labeling and tracking across the packaging process. It connected with production equipment, label printers, barcode scanners, operator interfaces, and the customer’s DSI ERP environment.
The implementation included:
API integration with the DSI ERP for production order and finished goods data
Automated pallet label generation using customer-provided printers
Barcode scanning to verify label readability and data accuracy
PLC integration using PalletWorks Add-On Instructions
FactoryTalk Optix screens for operator interaction
Offline operation during ERP communication interruptions, with queued data synchronization after connectivity is restored
Support for downstream pallet updates, including reweigh activity and label regeneration when required
This architecture reduced the number of separate tools involved in pallet processing and created a more maintainable connection between packaging automation and enterprise data.
When production equipment initiates a pallet event, PalletWorks generates the required pallet record and associates it with production information from the manufacturing process. The software then creates the pallet label and sends it to the appropriate printer.
Before the pallet continues downstream, barcode scanning verifies that the label is readable and that the data matches the expected pallet information. This verification step helps prevent incorrect or incomplete pallet data from moving further into the operation.
PalletWorks then synchronizes pallet and production information with the DSI ERP through API integration. When downstream changes occur, such as reweigh activity or required pallet updates, PalletWorks updates the pallet record and regenerates labels when needed.
If ERP connectivity is temporarily unavailable, PalletWorks can continue supporting defined plant-floor activity and resubmit data after communication is restored. This helps reduce disruption during connectivity interruptions while maintaining data integrity between packaging and business systems.
Cybertrol provided functional design, software configuration, PLC integration, HMI development, testing, commissioning, training, and documentation.
The project included review and approval of functional descriptions before programming began. Cybertrol then configured PalletWorks, implemented PLC communication, developed the FactoryTalk Optix operator interfaces, and completed integration with the ERP environment.
Factory acceptance testing was completed with the customer team before deployment. During startup, Cybertrol provided on-site and remote engineering support for communication checkout, functional testing, commissioning, operator training, documentation updates, and final handoff.
The PalletWorks implementation improved the customer’s ability to manage pallet labeling, tracking, and ERP synchronization across packaging operations.
Operational improvements included:
More accurate production and pallet data between the plant floor and ERP
Reduced manual entry and correction of pallet information
Improved traceability throughout the pallet lifecycle
Barcode verification before pallets moved into downstream processing
More consistent label generation and label data handling
Easier maintenance compared with custom-developed packaging applications
A configurable foundation for future packaging line enhancements
Improved ability to keep finished goods information aligned with ERP records
By implementing PalletWorks, the dairy manufacturer gained a more reliable way to manage pallet labeling and production data at the end of the packaging line while reducing dependence on manual processes and custom application maintenance.
PalletWorks helps manufacturers manage end-of-line production labeling, pallet tracking, barcode verification, operator interaction, and ERP integration within a configurable software environment.
For dairy, food and beverage, and other manufacturing operations, PalletWorks provides a practical path to improve packaging automation without building and maintaining one-off applications for each line or facility requirement.
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