Automated Food Pack Counting System Using Esp32 With Things Speak Monitoring

Abstract

The Automated Food Pack Counting System presents an innovative solution to common issues in the food packaging industry, such as manual errors, inefficiencies, and increased costs. Traditional counting methods often lead to inaccurate packaging and delays. This study proposes a low-cost, accurate, and scalable system using the ESP32 microcontroller integrated with the ThingSpeak IoT platform to automate the counting process and allow remote monitoring. The system uses sensors for real-time food pack detection and transmits the data to ThingSpeak for analysis via a user-friendly interface. Through iterative development, hardware-software integration, and calibration, the device has 100% detection efficiency of food pack counting and transmission data efficiency is about 99.8%, based on average delay in controlled conditions. It offers precise counting, real-time reporting, and data visualization, which are essential for improving decision making and supporting digital transformation in production lines. With this automation, manufacturers can reduce reliance on manual labour, improve packaging accuracy, and enhance overall operational efficiency. The solution proves practical for industries seeking cost-effective digital upgrades and better production monitoring.