Collaboration on Deal2’s Pallet Wrapping Machine Management System

Deal2 and Its Pallet Wrapping Machines

Deal2 is a company specialized in distributing pallet wrapping machines that use transparent stretch film, with a strong focus on the Spanish market. Its client portfolio includes major accounts such as Carrefour and Zurita, companies with a very high transport volume that generate thousands of pallets to be wrapped every day.

The hardware behind Deal2‘s wrapping machines is based on PLCs capable of controlling the machine while simultaneously tracking highly detailed usage metrics: the pre-stretch percentage of each film roll (before and after entering the machine), the duration of each cycle, the number of cycles completed, and many other operating variables.

However, Zeus, the management system Deal2 was using, wasn’t developed enough to track the machines’ real performance or to offer performance dashboards to its clients. On top of that, another challenge arose: no software on the market was capable of managing machines as specific as Deal2‘s, given their custom design and very particular use cases.

For this reason, at TechsBCN we built Deal2 a fully custom management system that lets them define the parameters for each machine, provides an operational dashboard for clients, generates alerts for abnormal usage, manages clients and locations, and controls access for every user of the system.

A Custom Build at Multiple Levels

The volume of logs generated concurrently by all of Deal2‘s machines is extraordinarily high. To handle this data ingestion, it was necessary to rely on a NoSQL database (MongoDB), capable of scaling horizontally and storing large volumes of real-time information.

Alongside this ingestion layer, a complete enterprise application was built on .NET, backed by a SQL Server transactional database for all business logic. This balance between a NoSQL database for massive ingestion and a relational database for operational management was key to meeting the project’s various requirements.

For the front end, the team chose Blazor, enabling a modern, maintainable interface built with .NET technology end to end. Long-running background processes, such as log ingestion and processing, are handled through queues with RabbitMQ, ensuring the system’s reliability even under very high load peaks.

The Result

Thanks to this development, Deal2 now has a platform that didn’t exist on the market, tailored down to the last detail to the specific needs of its wrapping machines. Its clients, such as Carrefour and Zurita, can now monitor the real performance of their equipment and receive alerts for any abnormal behavior.

At TechsBCN we are proud to have met a challenge as specific as Deal2‘s, combining massive data ingestion technologies with robust enterprise development, once again demonstrating our ability to build custom solutions where the market falls short.