Custom Special Machine Construction and Intelligent Conveyor Technology – Perfectly Combined

for automated identity verification and IO/NIO sorting

Customer requirement

For the incoming goods area of film-wrapped flat goods, an automated solution was required that reliably identifies items, detects faulty products, and sorts them without manual intervention. RFID, barcode, and AI-supported code reading technologies needed to be integrated into a continuous conveying process. At the same time, the system had to be seamlessly integrated into existing conveyor technology and the current IT landscape, and serve as a scalable prototype for future expansion stages.

Our solution

BKLS developed a fully automated sorter conveyor system that combines the expertise of conveyor technology and special machine construction into a tailor-made overall solution. The system handles the identity verification of film-wrapped flat goods and the automatic separation of IO and NIO items.

The system combines several conveyor modules with intelligent sensors, RFID and barcode detection, and automated rejection of faulty products. Conveyor technology, control technology, and individual machine design seamlessly interlock, enabling a continuous, secure material flow.

All conveyor belts, sensors, and sorting processes are coordinated via the integrated Siemens S7 control system. Communication with KEYENCE and identass identification systems takes place via defined interfaces, ensuring reliable real-time evaluation. The system is supplemented by safety devices according to the Machinery Directive, container and fill level monitoring, and remote maintenance options.

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less manual sorting and inspection effort

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Process reliability through automated identity verification

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faster incoming goods processes

Technical highlights

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Automatic IO/NIO sorting using conveyor and paddle system

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RFID, HF, UHF, and AI-supported barcode recognition

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Siemens S7 control with HMI, remote maintenance, and interface integration

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Conveyor speed up to 25 m/min

Cycle time:
3 seconds per part

Result

The automated sorter conveyor system resulted in a tailor-made overall solution that combines conveyor technology, special machine construction, and intelligent automation in one system. Automated identity verification and sorting reduce manual interventions, increase process reliability, and ensure continuous material flow. Thanks to its modular design and open interface architecture, the system can be flexibly integrated into existing production and logistics processes while also forming the basis for future expansion stages.