Pilz and Komet: Modern Safety and Control Concept Leads to Greater Packaging Productivity

Faster, more flexible, safer – with this objective in mind, the level of automation on plant and machinery continues to advance in all industries. Both safety and control technology take these high requirements into account. If necessary, powerful components can be combined to form complete systems, which guarantee safety on the one hand, and can increase productivity on the other. If the user can adapt technology to suit his requirements, then he has a cost-effective, tailor-made solution. In many industries, packing is still associated with manual work. Where man and machine work together, the risk of injury must be minimized to the greatest possible extent. Safety devices used to be viewed as obstructive and inconvenient, but today the
opposite is true: modern safety and control concepts make handling easier, and plant and machinery more productive.

Faster thanks to the new safety concept
The semi-automatic vacuum-packing machine feeds in the bottom foil via a roller; it is then transported via a chain drive. The foil is brought up to temperature in the forming chamber; a special compressed air/forming procedure and the appropriate tool are used to create the desired tray shape for each packaged product. Staff use both hands to insert grilled sausages into the tray-shaped plastic film, six pieces per row and per pack, before the conveyor moves on and another set emerges from the forming station. After the filling station comes the sealing station: The top film seal is fed through a second roller; a vacuum pump extracts the air and thereby the oxygen. This slows down the activity of the micro- organisms, while the inflow of nitrogen prevents the sausage slices from sticking together. Finally, the top and bottom film layers are impulse sealed under pressure in the sealing chamber. The product packaging is now secure and durable. At the machine outfeed, longitudinal and transverse cutters separate the packaged product into individual trays, which are then fed into transport crates via conveyor. Two coils wind up the residual film cut from both sides. Sprinter is the name of the latest development from Komet, manufacturer of semi and fully automatic vacuum packaging machines. The company is based in Plochingen,Germany, and has its roots in the butchers' trade. It's in this field in particular that Komet's table-top units are used, as they provide an airtight seal for everything that needs to be kept fresh and preserved. Even in the butchers' industry there appears to be an irresistible trend away from the skilled producer and towards industrial production; customers increasingly ask for ready- packed goods, so Komet is increasingly focusing on semi and fully automatic machinery. Flexible and quick to convert, they can pack items in up to eight parallel trays, depending on the packaged product and the size, with or without automatic infeed. Even non-food goods can be packaged and sealed efficiently using  automated packaging machines.
Another reason why the machine is called Sprint is because, in comparison to the previous model Quickvac 2000, it can convey products to their packaging more quickly, using a less complicated procedure. That's because of a modern safety and control concept, which Pilz developed for Komet. Designed for maximum compatibility: sensor technology, evaluation device and visualization o n the Sprinter, the multifunctional safety system PNOZmulti configures simpler, safer interaction between man and machine. The safety system has a modular structure and can be used flexibly to suit the application. Instead of wiring, the user configures the needed functions simply, in a configuration tool. This saves time, space and money because there is no longer any complex individual wiring and all the safety related functions are located in one housing. PNOZmulti is cost effective when monitoring four or more safety functions and can also undertake standard control tasks. By comparison the safety devices on its predecessor were simplistic and mainly based on individually wired switches and contactors. Large covers safeguarded wide-ranging potential danger zones such as the forming and sealing stations via switch contacts. The infeed area in between was narrow and only allowed a one-up arrangement.
On the Sprinter, the cover on the forming station is reduced to a minimum. Instead, an advance security slide ensures that it is impossible to reach into either the forming or the sealing station from the filling station. If the slide switch is not closed, the safety system will prevent the bottom film from being formed and stop pressing and heat-sealing in the sealing station. Propulsion drives and valves are switched off; the central PMI operator
terminal (Pilz Machine Interface) receives an error message, stating the cause and the source. Magnetic safety switches, PSENmag, monitor the mobile protective hood over the sealing station, the longitudinal and  transverse cutters, and the lower positions of the lift cylinder plus the security slide on the forming/sealing station. The PNOZmulti also monitors the E-STOP and the enablers that control the heaters and valves (pneumatic + hydraulic). The risk of injury from the packaging machine, therefore, is kept to a minimum, both during operation and in setup mode. "With PNOZmulti the machine has a flexible safety concept which is really easy to adapt to our requirements. Now the infeed area has a three-up arrangement, so assembly is quicker and easier, plus the machine is more productive", says Harald Janke, Technical Manager at Komet.

Solution for safety and standard
A modern control solution also fell within the scope of the cooperation between Komet and Pilz. The standard control technology on the Sprinter also comes in useful for automatic operation and setup mode. "People at Komet were unhappy with the existing control solution and were looking for an efficient alternative", recalls Ralf Kessler, Applications Engineer at Pilz. Now they are using a PMI operator terminal in conjunction with a Profibus Master. A soft PLC runs under the Windows CE operating system. The standard I/O modules are logged and controlled via the PSSuniversal. The Pilz centralized control platform covers the whole I/O periphery as one system and is universally applicable. Users have three options: pure safety applications, combined safety and standard applications or exclusively conventional/standard control  functions.
With the grey, standard head modules it is possible to use analog and digital standard inputs and outputs on the fieldbus systems, without a functional connection to the safety technology. On the Sprinter, the head module of the PSSuniversal is also connected to the PMI via Profibus-DP, just like the PNOZmulti. Due to the system's modular design, the PSSuniversal can be individually adapted specifically to meet the respective requirement. If any adaptations are required, modules can simply be expanded or exchanged.

Benefitting from expertise
Pilz was also contracted to complete the electrical design, prepare the circuit diagrams and carry out the programming, including commissioning. "As a small company with around 30 staff we are reliant on competent, reliable partners for our electrical design and programming; we need partners who know what's happening and know what's important to us", says Janke, "Here we found Pilz to be a suitable partner, their technical advice was superb and the collaboration with the Pilz staff ran smoothly." The competence of Komet in terms of automation technology, combined with Pilz's expertise in matters of control technology and safety, jointly produced a new vacuum packing machine that operates more productively and is therefore of greater value.
Pilz is a global company, as such, not all standards and information will be applicable worldwide. Please check with your local Pilz office to ensure your factory and/or machines meet local standards.

Packaged with care

Foodstuffs must be packaged precisely, safely and carefully. When positioning or spacing products, it is particularly important to avoid flattening or damage during the packaging process.
The “Dynamic Stocker” accumulator made by the French firm Euro Cri converts an irregular product flow at the output of a production machine into a regular flow, as found when packaging biscuits, for example. The accumulator gathers the unpackaged products as they arrive and creates a “buffer store”, which can be regulated according to the change in the material flow.
The greatest challenge was to arrange the packaging process so that it was 100% synchronous with the rhythm of the existing horizontal flow-packer. The flow-packer forwards incoming products in an irregular sequence. Development and design demanded an automation solution capable of controlling complex movements and handle various transport speeds simultaneously. The focus was on the movement of a total of six axes. It had to be possible to coordinate the axis movements with 100% accuracy, so that the various speeds at different points of the conveyor could be synchronised precisely and safely regulated.
Euro Cri opted for a Pilz motion control solution (PMC), which enables precise synchronisation of the respective motion processes.

Complete packaging solution
As a supplier of complete automation solutions, Pilz France supported Euro Cri from planning and development to implementation and commissioning.
The central element of the motion control solution is the controller-based PMCprimo 16+, which performs the complex motion and control functions.
Used in conjunction with the servo amplifiers PMCtendo DD and servo motors PMCtendo AC, the result is a drive solution which can react flexibly to different format specifications and can be used to implement high cycle counts with ease. The absolute position of the motors can be read during operation, after the machine is shut down or after power failure. Systems with PMCtendo are modular and expandable. As a result, users can react flexibly to product changes. In addition to simplifying positioning and storing motion tasks, the PMCtendo DD also provides the power supply and motor drive on the “Dynamic Stocker”.

Packaging process is safely monitored
The packaging process can be monitored and regulated using PMIvisu operator terminals. The motion curves relevant for the cycle are calculated in the simplest way possible: the operator simply enters the set data on the operator terminal – the packaging length and the position of the section to be embossed, etc – and the system automatically calculates the motion profile for runtime. Adjustments are made via the operator terminal, whereby the material flow control system fulfils different product type requirements. The display can be used not only to select recipes but also to view error messages. The cause of the error always appears first; at the touch of a button the operator receives specific instructions on how to rectify the error.
Safety-related functions such as emergency stop, emergency off, or safety gate monitoring on the “Dynamic Stocker” are monitored via the compact safety relay PNOZsigma. The PSENmag safety switch was incorporated into the safety gate to ensure the packaging process is not interrupted unnecessarily; it is suitable for the very highest hygiene requirements and provides one hundred per cent protection against defeat.
“With Pilz we have gained a competent partner in the automation industry. We will continue to work with them in the future to develop leading-edge packaging systems for our customers,” says Mathieu Carie, Head of Automation at Euro Cri.



Author: Yannick Le Héno,
International Sales
Market Development
Pilz GmbH & Co. KG

Langen Packaging Inc. Chooses Pilz Automation Safety L.P. For Safety Applications

Langen Packaging Inc., a recognized leader in the packaging industry, has partnered with Pilz Automation Safety for safety related machine guarding applications.
Using multiple base units that can easily communicate with each other, Pilz hardware and software gives Langen the ability to distribute safety devices around the entire machine. “This allows us to build independent machine modules that can be interconnected with very few electrical connections,” said Langen electrical engineering manager, Patrick Strauss. “This aids in wiring, shipping and generally in pre-building standard modules.” Langen also has the ability to view the status of all safety I/O available, over Ethernet I/P, so that individual guard statuses can be easily reported on the HMI. Because the individual guard statuses are now easily accessible, Category 4 safety can be reached while only wiring two contacts per door, reducing the cost of door switches and wiring. Before using the PNOZmulti, up to three contacts per switch were required to be wired in order to have individual guard door statuses available at the HMI, the safety was only rated Category 3. Using the PNOZmulti, Langen is now able to easily create more complex safety zoning and sequencing. The Pilz system includes some modules that aren’t available on other safety controllers, including speed sensing modules, allowing complex safety functions when needed.
The new system has also aided in the reduction of manufacturing costs. Langen now has the ability to purchase the simplest light curtains because the PNOZmulti can handle tasks such as muting which the light curtain no longer has to be able to do on its own. “Pilz was able to offer the best flexibility and power within the price range,” notes Strauss.
The PNOZmulti is multifunctional and freely configurable for use in many areas of mechanical engineering. The safety system monitors safety functions such as E-STOP, safety gates, light beam devices, two-hand switches and much more. PNOZmulti can also be used to resolve standard control functions economically. Instead of wiring, users can generate the safety circuit on a PC using an intuitive configuration tool. The configuration is stored on a chip card and inserted into the base unit.
Langen Packaging has enjoyed great success in using the Pilz solution and is always involved in the development of future products and improvements by Pilz.


The world leader is SAFE automation; Pilz Automation Safety L.P. offers a full range of leading-edge safe automation products and services. The company’s innovative technologies and safety expertise provides customers with the leanest and safest solutions.
Products include sensor technology, electrical monitoring relays, automation solutions with motion control, safety relays, programmable safety and control systems and an operating and monitoring range. Wireless and safe bus systems are also available for industrial networking.
Pilz also provides a comprehensive range of consulting, engineering and training services. Certified consultants provide a wide range of services worldwide such as risk assessment, safety concept, safety design, CE services and safety sign-off. To keep a company LEAN and SAFE, there is no better partner than Pilz. For more information about Pilz Automation Safety L.P. or packaging solutions visit http://www.pilz.us/ or 734-354-0272.

Langen Packaging Inc. is North America’s foremost designer and manufacturer of high-speed cartoning and case packaging machinery, as well as integrated packaging solutions, ranging from standard models through to customized packaging lines. In the last several decades, Langen has become an advanced solution provider, integrating cartoners, accumulators and case packers into complete turn-key systems, taking on projects ranging in value from a few hundred thousand dollars to over $10 million. For more information about Langen Packaging visit http://www.langeninc.com/ or call 905-670-7200.

Motion Control for Packaging Machines

In today's competitive atmosphere, shorter innovation cycles and flexibility are vital to packaging companies wanting to rise above the competition. We are continually hearing from machine builders and Original Equipment Manufacturers (OEMs) about these challenges and the complexities they bring to machine operator safety and the pressure to do this efficiently.


Further, this demand has resulted in the decrease of batch build and multi-pack runs and now requires machinery to produce multiple packaging variations from the same machine. Adapting to this means the ability to perform quick product changeovers while maintaining a high level of throughput productivity.

Ultimately this impacts the machine operator's ability to perform quickly and safely. This reality has driven the industry to look into alternative solutions. Automation, coupled with motion control is the key to accomplishing this. However, the increase in motion requires a robust safety system to monitor and control these added moving components. For safety processes to run quickly and smoothly systems require multiple axis controllers, additional motion control devices and they must meet industry standards.

When these modified systems are deployed properly you will achieve the required flexibility and observe an increase in the throughput of products. One last issue to accomplishing this is choosing the right safety products to fit system needs.

When looking for motion control products it is important to look at the overall picture. First of all, motion control is needed to manage the movement of any highly dynamic drives and camshafts, synchronization of a wide range of decentralized drives to keep manufacturing safe at a low cost and at a consistent quality. Second, quick setup and maximum flexibility, as well as the ability for automatic adjustment to product variances are essential. Finally, the handling and robotics of a packaging machine is as an integral part of a complete automation solution.

Any and all motion control products must include the following: PLC to control the machine, optimum movement management on decentralized drives for motion control and an individual safety solution customized with integrated software and tools that meet universal, local and federal legislations.

Packaging specific applications and motion control components should also be adaptable for individual requirements. The ability to join together safety and industrial standards is a crucial element in any motion application. Equally imperative, safety must be integrated within the drive to make sure that every law of motion is available, optional real or virtual master axes and all additional tools able to suit the task of a specific packaging machine.

It is important to note, that a control solution should also be platform-independent. Integrated soft PLC in accordance with IEC 61131-2, can fast scan time from < 50us for 1000 instructions and no adjustments are required to change platforms. Thus, all of the automation in one project with support for modular structures, large selection of field buses, extensive libraries, motion control, interpolation and OPC Server, can positively impact both safety and productivity.

In further examining comprehensive motion control functionality, always consider this indispensible checklist to discern the most important features within any motion control product:

• Virtual main shaft and cam synchronization

• Integral "flexible cam"

• Register control

• Web tension control

• Linear and circular interpolation

• Electronic camshaft and safe motion within the drive

When choosing safety products for your packaging machines choose a company that is aligned with your priorities and use the above checklist to ensure you're making the best choice possible.