Automated Sortation System - Melbourne, Australia

High-efficiency automation for a leading international tea supplier

Pac Technologies was engaged to deliver the complete automation, control, and HMI system for a new carton sortation lin

e installed at a major tea distribution facility in Ravenhall, Victoria.The project formed part of a broader logistics upgrade aimed at increasing throughput, improving traceability, and reducing manual handling within the packaging and dispatch areas.

System Description

The automated sortation line is designed to move packed cartons from the induction area to their assigned sort lane with precision and zero-pressure accumulation. Each carton is identified via barcode, matched against the site database, and routed to its designated lane through a series of powered transfer modules.

The system features:

• A network of 13 conveyor lanes, including dedicated reject and accumulation zones.

• Multiple F-RAT (right-angle transfer) diverters that automatically direct cartons to the correct lane.

• Integrated barcode scanning for real-time identification and tracking.

• Zero-pressure accumulation technology to ensure smooth, damage-free carton handling.

• Intelligent blocking logic to prevent congestion at full lanes.

When the barcode system detects a carton without valid data, it is automatically sent to the reject zone for operator review.

Control System and HMI

At the core of the system is an Omron NX102 PLC, communicating via EtherCAT and Ethernet/IP to manage hundreds of motors, sensors, and control cards.The custom HMI provides operators with a full overview of system performance, including:

• Live lane monitoring and scan history.

• Individual motor and sensor diagnostics.

• Maintenance and device control screens for detailed fault analysis.

• Real-time counters and database connectivity for production reporting.

Safety was prioritised through dual emergency circuits, safety relays, and multiple local e-stops, ensuring full compliance with Australian standards.

Benefits and Outcomes

The installation has delivered a fully automated, data-driven solution that dramatically improves operational efficiency. Key outcomes include:

• Increased throughput through continuous, zero-pressure flow.

• Improved accuracy via integrated barcode validation.

• Reduced downtime thanks to real-time fault visibility and remote diagnostics.

• Enhanced safety with system-wide emergency control and interlocking logic.

• Scalable architecture designed for future expansion and software integration.