Coalmont designed and installed a standalone high-speed bottle counting system for two production conveyors, providing reliable product tracking independent of plant systems. The standalone architecture was required as this was a validation project that needed to run separately. Accurate counting at production line speeds presents significant challenges—sensor positioning, signal timing, and data processing must be precisely coordinated to avoid missed or double counts as bottles pass at high velocity. 

Our solution features Banner through-beam sensors with precise mounting on custom 80/20 aluminum structures to ensure reliable detection at full line speed. An Allen-Bradley CompactLogix PLC handles high-speed data processing, with Ignition SCADA providing the operator interface through 3-client licensing and a 32-inch display for enhanced visibility. The system delivers 3-day combined totals, hourly counts, automatic daily reset, date/time stamping, and internet connectivity for automated report forwarding. 

The project highlights a practical, cost‑effective manufacturing solution developed and fully shop‑tested prior to field installation. Altium Packaging gained accurate high-speed production counting for validation purposes, detailed historical logging for management decision-making, scalable architecture supporting future expansion, and reliable operation with UPS power protection. Our comprehensive approach included mechanical design, electrical installation, software development, and complete commissioning with operator training.