Cigarette Aligner Feeding System for a major Public Limited Company – Digital Twin Enabled Automation

Client

Public Limitec Company (FMCG – Tobacco & Cigarettes Division)

Industry

Food & Beverage / FMCG

The Challenge

Company’s high-speed cigarette production lines relied on manual alignment and feeding of delicate cigarettes into the packaging machines. This created frequent misalignment, product damage, inconsistent line speed, and high labour dependency. The manual process limited output, increased waste, and made it impossible to achieve consistent 100% orientation at the required takt time. With rising export demand and strict quality standards, client needed a fully automated, zero-damage solution that could be commissioned quickly without disrupting ongoing production.

Invensys Solution

Invensys Engineers designed, manufactured, and commissioned a custom Cigarette Aligner Feeding System. The solution integrates precision vibratory feeding, servo-controlled orientation, and real-time vision guidance. A digital twin was created during the design phase to simulate the entire system, validate cycle times, and eliminate potential issues before any metal was cut.

Key Technical Features

High-speed vibratory bowl feeder with custom escapement mechanism
Servo-driven orientation and placement unit with ±0.5 mm accuracy
Multi-camera vision system for 100% real-time alignment verification
Digital twin simulation (completed before fabrication) for cycle-time optimisation
Gentle handling technology to prevent cigarette damage or crushing
Seamless integration with existing packaging line and MES system
PLC/SCADA control with real-time OEE dashboard

How Digital Twin Delivered Results

Using digital twin technology, Invensys simulated 45,000+ cycles in a virtual environment. This identified and resolved 7 potential bottlenecks during design, reducing physical commissioning time by 40% compared to traditional methods. The system was installed and fully operational within 3 weeks of arrival at site.

Measurable Results

100% consistent part orientationachieved
Line speed increased by 28%(no more manual intervention)
Zero product damage or misalignment since commissioning
40% reduction in commissioning timedue to digital twin validation
Labour requirement reduced by 4 operators per shift
ROI achieved in under 9 months

Products & Systems Delivered

Special Purpose Machine (SPM), Cigarette Aligner Feeding & Orientation System with Digital Twin Integration

Proven Results. Trusted by Global Automotive Leaders.

Client Voice

Invensys not only solved our alignment problem but also used digital twin technology to deliver the system 40% faster than expected. The machine runs flawlessly 24/7 with zero damage and has become a benchmark for our other lines. Their combination of precision engineering and modern simulation tools is truly world-class.