Automatic Filling System
Smart Dispatching · Food-Grade Design · Full-Stack In-House
ZGL-V3.0 Smart Dispatching
Proprietary smart scheduling algorithm, real-time monitoring of multiple forming machine hopper levels
Food-Grade Safety Design
Full 304 stainless steel, non-stick PTFE coating, Ra 0.8μm mirror-finish welds, tool-free quick disassembly
Full-Stack In-House Manufacturing
Cart/rail/lift independently designed, Huichuan Codesys PLC+servo, Schneider LV electricals
Technical Specs
Industry Background
China’s frozen food industry has an annual output value exceeding 100 billion RMB. Automation upgrades are driven by three key factors: labor shortage, increasing food safety requirements, and capacity competition.
Pain Points
Low Efficiency
- 21 forming machines with only 36L hoppers, emptied in minutes
- Workers constantly moving carts between machines
- Frequent refilling: every 8 minutes per machine
- Delayed refilling leads to production line stoppages
High Labor Intensity
- Manual cart pushing, repetitive heavy work
- Slippery workshop floors pose safety risks
- Manual filling spillage loss approx. 5%
System Components
Lift
Dual-arm clamping, worm gear self-locking, safety guard with light projection, ≤30s lifting cycle
Smart Cart (Core)
300L hopper, 304 stainless steel + PTFE, dual servo independent control, quick-clean detachable
Rail System
100×150×4mm stainless steel tube, safety factor 4.8, modular sections, drip tray + dual limit
Filling Structure
Sealed connection above each forming machine hopper, splash-proof, quick-detachable
Control System
Huichuan Codesys platform, 18-inch industrial touch panel, real-time monitoring of 21 stations with MES integration
Cleaning System
Fixed and mobile dual cleaning platforms, high-pressure water gun with hose reel, wastewater drainage collection
ZGL-V3.0 Smart Dispatching Algorithm (Core)
Real-time data acquisition of 21 forming machine hopper levels, intelligent priority ranking (lowest level first), route optimization (same priority sorted by distance), auto-return when cart is empty, auto-skip disabled stations. Records filling count and volume per machine, tracks cart trajectory for efficiency analysis, and logs fault alerts for predictive maintenance.
Cycle Time & Capacity Verification
| Item | Value |
|---|---|
| Filling consumption per machine | 200 pcs/min × 12g = 2.4kg/min |
| Refill interval | (28-8)kg / 2.4kg ≈ 8.3 min/machine |
| Cart time per machine | Travel 5s + Position 2s + Dispense 16s + Accel 2s ≈ 25s |
| 10-machine cycle | 250s ≈ 4min10s + return refill ≈ 5min |
| Margin | 5min cycle vs 8min shortage, 1.6× margin |
Result: Cart refills in 5min cycles, machines run out in 8min — 1.6× margin ensures no downtime.
Capacity Verification
| Metric | Value |
|---|---|
| Tender Requirement | ≥ 1.8 tons/h |
| Proposed Solution | 2.5 tons/h |
| Actual Consumption | 1.44 tons/h |
Cart capacity far exceeds actual demand. Even at 220 pcs/min (+10% consumption), the system stays well within capacity.
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