P&G Cabuyao – 2-Lane Servo Capper Automation 2025
TDL delivered the complete automation of a new 2-lane capper for P&G Cabuyao in the Philippines, working for the machine builder: servo capping, automatic size changeover, safety circuits and the operator interface, from the bench to start-up on the line.
Key Facts
| End user | P&G Cabuyao |
|---|---|
| Contracted by | Machine builder |
| Location | Cabuyao, Philippines |
| Industry | FMCG |
| Year | 2025 |
| Machine | 2-lane servo capper with automatic size changeover |
| Controller | ControlLogix 5580 |
| Motion | Kinetix 5300 servo drives, integrated motion on EtherNet/IP |
| Size changeover | Networked positioning drives on EtherNet/IP |
| I/O & network | POINT I/O, PowerFlex 525, Stratix 5200 |
| Safety | Guardmaster 440C safety relays |
| Machine states | PackML (ISA-TR88.00.02) |
| Third-party inspection | TÜV Rheinland – passed |
| TDL role | Full-scope machine automation, FAT/SAT and on-site commissioning |
Scope of Supply
- Motion control: Integrated motion on EtherNet/IP: on each lane, Kinetix 5300 servo axes drive the capping spindles, cap head, cap stripper and bottle transporter, with speed and position set from the HMI.
- Automatic size changeover: Recipe-driven changeover between bottle formats. Networked positioning drives reposition the neck grabbers, cap chuck, bottle stopper and guide rails in staged steps; the order of the steps reverses depending on whether the change is to a larger or a smaller bottle, so that the mechanisms clear each other.
- PLC and HMI: ControlLogix 5580 program structured on the PackML state model with ISA-88 equipment and control modules; HMI with Auto, Manual and Dry Run modes, per-lane manual pages, recipe editor, alarms, and interlocks with the filler and the cap sorter.
- Safety: Emergency stop and guard-door circuits on Guardmaster 440C configurable safety relays, with reset and status handled by the PLC; energy isolation per lane.
- Hardware: Control panel supply and electrical installation on the machine: POINT I/O, PowerFlex 525 conveyor drives and a Stratix 5200 managed switch.
- Testing & commissioning: FAT and SAT, and on-site commissioning with integration into the existing packing line. The machine passed third-party inspection by TÜV Rheinland against the Machinery Directive, EN 60204-1 and EN 415-10.
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