INTERLOCK AUTOMATION & ROBOTICS
PRODUCT LINEUP
A complete ecosystem of automation, robotics, AGVs, digital twin systems, energy optimization and industrial AI
Engineered for next-generation cement factories.
6-Axis Palletizing Robot – Cement Bags
| Parameter | Typical Specification | Notes |
|---|---|---|
| Application | Palletizing 50 kg cement & powder bags | End of rotary packer, inline or 90° layout |
| Payload | Up to 50 kg per pick | Single or twin-bag pick depending on pattern |
| Axes | 6-axis articulated robot | Industrial robot arm with controller |
| Reach | 1.8 – 2.2 m horizontal | Covers infeed conveyor + pallet station |
| Repeatability | ±0.05 – 0.07 mm | Model-dependent |
| Throughput | 8 – 12 bags/min per robot | Pattern, infeed and gripper design dependent |
| Gripper | Bag clamp / hybrid bag gripper | Custom-designed for cement bags |
| Protection | IP65 arm, dust kit for cement | Extra covers in heavy-dust zones |
| Safety | Safety controller, scanners, fencing | Complies with industrial robot safety standards |
| Integration | PLC, packer signals, digital-twin system | Real-time monitoring and diagnostics |
7-Axis Palletizing & Lorry Loading Robot
| Parameter | Typical Specification | Notes |
|---|---|---|
| Application | Extended-reach palletizing & direct lorry loading | Truck bay or dock loading areas |
| Axes | 7-axis articulated robot | Extra axis for reach and obstacle avoidance |
| Payload | 30 – 60 kg per pick | Depends on robot model and reach |
| Horizontal reach | Up to ~3.0 m | Can reach deep into lorry body |
| Vertical reach | Floor to lorry deck / high pallets | Mounted on base or gantry if required |
| Position feedback | Lorry position sensors & laser markers | Adapts pattern to different truck models |
| Safety | 3D scanners, safety zones, E-stops | Safe operation around truck & operators |
| Integration | Packer conveyors, diverters, yard system | Connected to plant SCADA / digital twin |
Packing Line Automation – Rotary Packer & Bag Flow
| Subsystem | Typical Specification | Notes |
|---|---|---|
| Rotary packer | 8–12 spout cement packer, 50 kg bags | Existing or new machines supported |
| Bag discharge | High-speed belt + alignment conveyors | Smooth transfer to check-weigher & robot |
| Check-weigher | ±0.5 kg accuracy at full speed | Integrates with AI chamber & reject |
| Reject system | Automatic push-off or diverter | For under/over weight or damaged bags |
| Control system | PLC + safety PLC where required | Interlocks with robots, AGVs & packer |
| Data | Bag count, tonnage, downtime, alarms | Sent to digital twin dashboards |
AGV Forklifts – 1 to 4 Ton Capacity
| Parameter | Typical Range | Notes |
|---|---|---|
| Capacity classes | 1.0 t · 1.5 t · 2.5 t · 4.0 t | Standard pallet & jumbo-bag handling |
| Lift height | 3.0 – 6.0 m | Single or double mast options |
| Navigation | Laser SLAM / natural feature | Optional markers or QR codes in tough areas |
| Speed | Up to 1.5 m/s | Limited by safety and site layout |
| Position accuracy | ±10–20 mm at pallet stations | For auto pick/place at conveyors & racks |
| Battery type | Lithium-ion traction pack | Fast charge, long life |
| Runtime per charge | 8–16 hours (typical duty cycle) | With opportunity charging strategy |
| Safety devices | 360° laser scanners, bumpers, blue lights, audible alarm | Meets industrial AGV safety requirements |
| Fleet management | Central traffic & mission manager | Interfaces with WMS / yard & digital twin |
Collaborative Robots (Cobots)
| Parameter | Typical Range | Notes |
|---|---|---|
| Payload | 3 – 20 kg | Light pick-and-place, case packing, QA |
| Reach | 0.8 – 1.3 m | Model dependent |
| Axes | 6-axis cobot arm | Multi-directional reach |
| Safety | Force-limited joints, monitored stop, safe speed | Designed to work close to people |
| Programming | Graphical interface & hand-guiding | Optional offline programming |
| Mounting | Table, floor or mobile base | Quick redeployment between lines |
| Integration | Vision systems, labelers, conveyors | Connected to PLC or standalone |
Lorry Loading Automation – Cement Bags
| Subsystem | Typical Specification | Notes |
|---|---|---|
| Infeed conveyor | High-speed bag conveyor from palletizing / packer | With metal detectors & bag alignment |
| Diverter / sorter | Motorized diverter to multiple loading bays | Selectable truck lanes |
| Truck position sensing | Laser scanner / photo sensors | Ensures correct loading position |
| Robot loading | 7-axis bag-loading robot(s) | Custom patterns inside truck body |
| Operator interface | Digital-twin tablet with truck ID, bag count & status | Real-time progress for dispatch office |
| Safety | Safety scanners, E-stops, safe zones around trucks | Interlocks with gate barriers & truck brakes |
AI Quality-Control Chamber – Bag Inspection
| Parameter | Typical Specification | Notes |
|---|---|---|
| Inspection type | Surface damage, leakage, print & label checks | Computer vision / AI models |
| Weight check | Integrated check-weigher, ±0.5 kg @ full speed | Rejects over/under weight bags |
| Cameras | 2–6 industrial cameras (top & sides) | High-speed synchronized capture |
| Lighting | Enclosed LED lighting with glare control | Stable images in dusty environments |
| Processing unit | Industrial PC or edge AI module | On-prem inference with remote updates |
| Throughput | Matches packer speed (e.g. up to 2,400 bags/hr) | No stop-and-go required |
| Data logging | Defect images, reason codes, statistics | Sent to digital twin & QC reports |
Nemotech Bag Shooter – Automatic Valve Bag Applicator
| Parameter | Typical Specification | Notes |
|---|---|---|
| Compatible bag type | Paper / PP valve bags, 50 kg (other sizes on request) | Single- or multi-ply valve sacks |
| Bag dimensions | Typical width 450–550 mm · length 720–950 mm | Exact range depends on model and change parts |
| Magazine capacity | Up to 250–400 bags per magazine | Side-loading for easy refilling |
| Max. speed | Up to 2,400–3,000 bags/hour (per line) | Matched to rotary packer output |
| Bag transfer method | Vacuum pick-up + mechanical shooting head | Positive placement on each spout |
| Packer interface | Synchronised with rotary packer PLC / encoder | Adjustable timing for each spout |
| Air supply | Clean, dry compressed air, ~6–7 bar | Consumption depends on speed and configuration |
| Power supply | 3-phase, 380–480 V, 50/60 Hz | Control panel with VFDs & PLC |
Robot-Arm Bag Inserter – Automatic Valve Bag Placement
| Parameter | Typical Specification | Notes |
|---|---|---|
| Robot type | 4- or 6-axis industrial robot | Model selected based on reach & speed |
| Payload | 5–15 kg | Enough for single valve bag + gripper |
| Reach | 1.2 – 1.8 m | Covers bag magazine and packer spouts |
| Bag type / size | Paper / PP valve bags, 25–50 kg range | Gripper fingers / suction cups tailored to bag |
| Magazine | Stationary or indexable magazine, 200–300 bags | Refilled from pallet or bundle |
| Cycle time | As low as 1.0–1.5 s per bag (optimised) | Supports high-speed rotary packers |
| Placement accuracy | ±2–3 mm at spout position | Ensures full seal on valve |
| Bag detection | Vacuum sensors + optional 2D camera | Checks bag pick quality & orientation |
| Packer synchronisation | Encoder / trigger from packer PLC | Robot tracks spout position in real time |
| Safety | Safety controller, light curtains / scanners, fencing | Safe area around robot & maintenance doors |
| Integration | Full interface with packer, conveyors & digital twin | Bag count, OEE, alarms and maintenance data logged |
DIGITAL TWIN TECH SPEC
| Parameter | Typical Specification | Notes |
|---|---|---|
| System purpose | Real-time 3D/2D monitoring of robots, AGVs, packers, conveyors, QC and loading systems | Centralised view of full dispatch & packing operations |
| Data sources | PLC tags, SCADA, AGV fleet manager, AI cameras, weighing systems, sensors | Supports OPC-UA, Modbus TCP, MQTT, REST API |
| Refresh rate | 100–500 ms for machine status, 1–3 s for motion assets | Low latency using edge gateway |
| 3D visualisation | Digital twin model of packer, robot cells, conveyors, staging, warehouse & loading bays | Matches real plant layout & coordinates |
| KPI dashboard | OEE, tons/hour, bags/min, queue time, truck turnaround, downtime & alarm logs | Shift-wise & grade-wise reporting |
| AI insights | Predictive alerts for bottlenecks, QC deviations, slow cycles & AGV delays | Rules-based + ML models available |
| User interfaces | Web UI, tablet UI, large display for control room | Role-based access for GM, dispatch, QC, maintenance |
| Server requirements | Industrial PC / server with 16–32 GB RAM, SSD, optional GPU | On-premise or cloud deployment |
| Security | Encrypted comms, ACL, audit logging, gateway isolation | Supports plant cybersecurity standards |
| Integration | Fully linked with packer PLC, robot inserter, shooter, palletizer, AGV and lorry loading | OEE, bag count, QC, alarms all logged centrally |
PLC & Electrical Control Panel – Technical Specifications
| Parameter | Typical Specification | Notes |
|---|---|---|
| PLC brand / model | Siemens S7-1500 / Allen-Bradley CompactLogix | Selection based on client standard |
| I/O capacity | 200–600 digital / analog I/O per line | Expandable modular cards |
| Communication | Profinet, Ethernet/IP, Modbus TCP, OPC-UA | Used for SCADA, robots, AGV integration |
| Safety system | Safety PLC + SIL2/SIL3 safety relays | Light curtains, area scanners, E-stops |
| HMI | 7–15” touchscreen interface | Bag recipes, alarms, manual controls |
| Ingress protection | IP54 / IP55 rated panels | Suitable for cement plant dust conditions |
| Power supply | 24VDC control, 415VAC main | Surge protection & isolation included |
| Cable management | Industrial cable trays, armored field cables | Noise-protected routing for sensors |
| Monitoring | Panel temperature, power status, IO diagnostics | Data forwarded to digital twin |
Palletizing & Warehouse Automation
| Subsystem | Typical Specification | Notes |
|---|---|---|
| Pallet feed | Automatic pallet dispenser, 15–25 pallet capacity | Supports wooden & plastic pallets |
| Bag pattern | 3-2, 4-3 or custom patterns | Approx. 10 layers = 50 bags / 2.5 t |
| Pallet wrapping | Automatic stretch wrapper with top sheet option | Dust and rain protection for dispatch |
| Pallet labelling | Barcode / QR label printer & applicator | For WMS & truck traceability |
| Staging area | Motorized or gravity roller conveyors | Handover to AGV forklifts or manual forklifts |
| Warehouse integration | AGV routes, rack positions, WMS link | Full digital-twin visibility of stock |
Conveyors & Diverters – Technical Specifications
| Parameter | Typical Specification | Notes |
|---|---|---|
| Conveyor type | Belt conveyor for bags / pallet conveyors for wrapped pallets | Custom length & width |
| Material | Steel frame with rubber belt or PVC belt | Dust-resistant structure |
| Motor / drive | 0.75–2.2 kW motors with VFD control | Speed adjustable for flow balancing |
| Speed | 20–45 m/min (bags) | Matches packer discharge rate |
| Bag sensors | Photoelectric / ultrasonic sensors | Detect bag count & spacing |
| Diverter type | Pneumatic pusher / swing-arm diverter | Directs bags to QC or reject line |
| Reject mechanism | Pneumatic kicker / air blast | Linked to AI QC chamber |
| Safety | Emergency pull cord + guards | Conforms to conveyor safety norms |
| Integration | Fully controlled via PLC & linked to digital twin | Bag flow visible in real time |
Green Energy System – Solar, Battery & AI Optimization
| Subsystem | Typical Specification | Notes |
|---|---|---|
| Solar PV | Rooftop / ground-mount, scalable 250 kWp – 5 MWp+ | Designed for plant roof, warehouses and yards |
| Battery storage | Battery energy storage system (BESS), 250 kWh – 5 MWh | Supports AGVs, robots and plant loads |
| Inverters | String / central inverters with plant SCADA interface | Grid-tied, hybrid or islanded modes |
| Monitoring | Real-time dashboards for generation, consumption & SOC | Integrated into digital twin platform |
| AI optimisation | Algorithms for load shifting & peak shaving | Optimises energy cost per ton of cement dispatched |
| ESG & reporting | CO₂ reduction, kWh/ton and savings reports | Supports ESG and sustainability reporting |
System Safety & Compliance – Technical Specifications
| Parameter | Typical Specification | Notes |
|---|---|---|
| Safety category | CAT3 / CAT4 according to ISO 13849 | Robot & AGV zones separately certified |
| Robot safety | Light curtains, area scanners, safety PLC | Automatic stop on intrusion |
| AGV safety | 360° LiDAR, bumper sensors, warning beacons | Safe stop zones & route monitoring |
| Electrical safety | MCCB, MCB, E-stop, overload protection | All panels comply with IEC 60204 |
| Documentation | Risk assessment, SOP, lockout-tagout procedures | Provided for entire automation line |
| Audits | Annual safety audit recommended | Digital twin logs all events |
Ready to modernize your packing, palletizing & dispatch operations?
Share your current challenges — rotary packer issues, palletizer upgrades, AGV automation needs, AI QC requirements or energy optimization.
Our engineering team will design a complete Automation 4.0 roadmap tailored for your plant.