<![CDATA[General Background Thermoforming machines in the plastic manufacturing industry rely on plastic sheet rolls as the primary raw material that must be supplied continuously during production. Specific Background A critical operational issue occurs when plastic sheet rolls approach depletion while machines continue operating due to the absence of automated operator warning systems. Knowledge Gap Although automated monitoring is essential for stability, unmonitored material exhaustion frequently leads to excessive material waste and reduced manufacturing efficiency. Aims This article investigates the implementation of a plastic sheet roll depletion detection system on a thermoforming machine to provide early warnings for operators. Results Findings demonstrate that utilizing a photoelectric sensor and reflector successfully detects remaining sheet material and triggers alarms via relays to notify operators promptly. Novelty This work presents a functional field-tested automation setup integrating photoelectric sensing with machine PROFIBUS control for continuous plastic sheet monitoring. Implications Timely operator notifications support more effective, controlled production workflows and minimize material wastage in industrial manufacturing. Key Findings Highlights The automated detection system successfully identifies plastic sheet roll depletion using photoelectric sensors and reflectors, Relay integration effectively activates alarms to notify operators before complete material exhaustion occurs, Functional testing confirms the mechanism eliminates false alarms while ensuring smooth, uninterrupted manufacturing processes. Keywords Thermoforming Machine, Photoelectric Sensor, Alarm System, Plastic Sheet Roll, Industrial Automation]]>
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