HISTORY

Shriram Automation is a system integrator specializing in industrial automation solutions. They collaborate closely with OEMs (Original Equipment Manufacturers) to help design and build advanced machines by integrating cutting-edge automation technologies. Leveraging their technical expertise, Shriram Automation enhances machine performance, efficiency, and reliability, providing end-to-end support from concept to commissioning.

Gayatri Engineers is an OEM specializing in the design and manufacturing of textile machinery. They provide innovative, high-performance machines tailored to the needs of the textile industry. With a focus on quality, durability, and efficiency, Gayatri Engineers supports textile manufacturers by delivering reliable equipment that enhances productivity and meets modern production standards.

CHALLENGE

In a recent Material Handling automation project, Shriram partnered with Gayatri Engineers. The goal was to develop a fully automated material handling
system for managing textile rolls across multiple machines, with real-time tracking and smart routing to the packing area.

This was not a typical conveyor application—it involved complex logic, highspeed decision-making, and intelligent rejection systems. To meet these demands, Shriram recommended Horner Automation’s latest Canvas 7 platform, complemented by SmartStix I/O modules, for robust control and scalable performance.

SOLUTION

The textile material handling conveyor system was designed to handle textile rolls coming from different machines, guiding them to appropriate packing locations based on roll type and availability. The whole solution was comprised of:

• 11 Main Conveyors for transporting rolls
• 2 Buffer Conveyors for temporary storage and flow management
• 2 Doffing Systems for unloading finished rolls
• A Barcode Scanner for real-time roll identification and validation
• An Automated Rejection System for incorrect or unrecognized materials

The barcode scanner played a critical role, identifying the roll type and dynamically directing each item to its correct destination. This eliminated manual sorting, reduced errors, and increased operational efficiency.

So why the Canvas controller? The complexity of this application demanded a controller capable of handling multiple I/O points, real-time logic execution, and seamless communication with peripherals. The Canvas 7 controller was selected for these features:
• High processing speed to manage dynamic routing logic
• Modular and compact design for easy panel integration
• SmartStix I/O support enabling flexible and scalable connections
• Seamless interface with barcode scanners and other industrial devices

With the Canvas 7, Shriram was able to deliver a system that not only met current requirements but also offered the flexibility to scale and adapt as production demands grow.

KEY FEATURES & BENEFITS

• Intelligent Roll Routing: Barcode-driven logic ensures each roll is routed correctly, based on its ID and machine origin.
• Reduced Manual Intervention: Automated rejection and sorting processes eliminate human error.
• Buffer Conveyor Integration: Efficient management of material flow prevents bottlenecks.
• Scalable Architecture: SmartStix I/O modules provide easy expandability for future system upgrades.
• Enhanced Traceability: Barcode tracking adds traceability and data transparency in roll movement.

The implementation of the Canvas-based control system has led to significant improvements for Gayatri Engineers:
• Improved throughput and material flow efficiency
• Enhanced reliability with automated sorting and rejection
• A Modular System ready for future expansion or integration
• Reduced dependency on manual labor for roll identification and routing

CONCLUSION / TESTIMONIAL

This case study underscores the value of using modern control platforms like Canvas 7 in textile automation. With intelligent routing logic, modular I/O integration, and seamless peripheral communication, the solution developed for Gayatri Engineers stands as a benchmark in automated textile material handling. As textile OEMs continue to evolve, adopting such smart systems will be crucial for maintaining competitiveness, improving quality,
and achieving operational excellence.

“We’ve found the Horner PLC to be the best solution for our automation needs — it’s easy to use, incredibly durable, compact, and highly reliable. The all-in-one design simplifies our control systems without compromising on performance. Whether it’s for a small application or a complex machine, the Horner PLC delivers consistent results with minimal setup time. It’s truly a game-changer for anyone looking for a powerful yet user-friendly PLC solution.”
~ Sunit Gupte, Shriram Automation, Naupada, Thane, India