FILLING AND

PACKAGING
Packaging LEADERSHIP
2 | Packaging

WE ARE AT HOME
IN MANY
INDUSTRY SECTORS.
4 | Packaging

 VOLUME.

nnSolutions for filling plants

06
BEVERAGE INDUSTRY

nnSolutions for dairy

nnSolutions for meat processing

12
FOOD INDUSTRY

nnSolutions for pharmaceuticals

20
PHARMACEUTICALS

nnSolutions for pillow bag machines

nnSolutions for cardboard packaging machines
nnSolutions for palletizers/depalletizers

26
PACKAGING INDUSTRY

PRODUCTS 38
INDUSTRY 4.0 AND 42
SOLUTIONS WITH IO-LINK
ABOUT BALLUFF 48
REFERENCES 50
 Beverage industry | 7

Packaging in the beverage industry

AT RAPID PACE.
SMOOTH AND RELIABLE

Filling plants are characterized by high technical demands and

challenging environmental conditions. Sensors from Balluff are
ideal for these situations. They ensure that beverages are filled
aseptically and sterile, bottles are properly sealed and correctly
labeled. Balluff components enable high cycle rates as well as
fast and efficient filling processes.
8 | Beverage industry

Solutions
for filling plants

LEVEL MONITORING FOR

BOTTLING

DETECTING LIQUID IN
TRANSPARENT BOTTLES
LEVEL DETECTION
IN STORAGE TANKS

SEAL MONITORING

LABEL DETECTION ON
BEVERAGE BOTTLES
10 | Beverage industry

LEVEL DETECTION IN STORAGE LEVEL MONITORING FOR BOTTLING SEAL MONITORING

TANKS

After fermentation the green beer
matures for an additional time in storage
tanks before it can be filled. Balluff BSP
pressure sensors reliably detect the level
in the tank.
Features
Stretch blow molding machinery used
in the beverage industry to produce
bottles. The bottles can be filled
immediately and transport distances
eliminated. The high-precision SF fill level
sensor from Balluff monitors levels in
the filling process. The temperature can
also be monitored.
Checking seals in the beverage industry
requires that many different features be
inspected at the same time. The BVS
Vision Sensor meets these requirements
to ensure reliable monitoring.
Features

nnStainless steel IP69K housing, FDA nnRapid installation and configuration

conformal
nnMonitoring of hydrostatic pressure
even when positioned at a short
distance from the tank
nnAvailable with IO-Link
nnHygienic process fitting available
Features ensure short setup times
nnConvenient setup
nnEcolab-certified,3A approval,
FDA- and EHEDG conformal
nnHygienic interface with the production
environment
nnDynamic and precise
nnSaves space by combining measured
parameters (2 in 1)
LABEL DETECTION ON BEVERAGE
BOTTLES
Bottles are labeled after filling. Only
correctly labeled bottles may then be
packaged. This means the label applica-
tion process needs to be checked. Our
BOH optical sensor with separate ampli-
fier provides reliable information for mis-
sing or incorrectly placed labels.
Features
nnOutstanding operability and readability
of the processing electronics
nnCompact design
nnFast changing for different settings
and operating conditions
nnEasy retrofit
DETECTING LIQUID IN TRANSPARENT
BOTTLES
BGL fork sensors from Balluff use infra-
red light to detect all liquids with a water
component of above 15 %. They reliably
detect levels through transparent cont-
ainer walls. Our fork sensors are availab-
le in stainless steel with Ecolabcertificati-
on and in IP69L for hygienic areas.
Features
nnFast, reliable inspection
nnHigh output rate
nnAlso suitable for liquids in small,
transparent hoses with a small
diameter (≤ 6 mm)
nnHigh process reliability
nnCompact housing
nnNo adjusting required since the emitter
and receiver are already aligned
More information about our packaging solutions
in the packaging industry can be found at www.balluff.com
 Food industry | 13

Packaging in the food industry

PERFECTLY PREPARED.
HYGIENIC
AND HIGH QUALITY

DAIRY

The dairy industry is subject to the strictest hygienic and quality regulations. This is
why a real-time capable and transparent production process with modular production
lines is indispensable for efficient production. Only in this way, can traceability and
flexibility be ensured. Our comprehensive product portfolio enables you to optimally
configure your equipment and machines for meeting the demands of your customers.

MEAT PROCESSING

Cleanliness has the highest priority in the meat processing industry as well. Only if
hygienicstandards are taken into account when the machine is built can the desired
high quality of the end product be ensured. We offer a wide range of sensors for hy-
gienic areas that provide the greatest reliability even in harsh application conditions.
14 | Food industry

LEVEL DETECTION
IN A YOGURT TANK

Solutions for dairy

 CHECKING THE PRESENCE OF THE
CONTAINER FOR SECURE FILLING

OBJECT DETECTION DURING

PRODUCTION

COLORED LABEL DETECTION

VEHICLE DETECTION
16 | Food industry
LEVEL DETECTION IN A YOGURT TANK
Level detection in the production of
yogurt or quark requires sensors that
can meet especially high requirements.
Our capacitive immersion sensor BCS
features very good adhesion compensa-
tion. It detects the level of milk products
with absolute reliability. The steel tanks
used are prepared for hygienic installa-
tion of the sensors by the use of confor-
mal fittings.
Features
nnReliable when used for high-
conductive and liquid, sticky foods
nnEHEDG conformal, FDA approved,
in IP69K
nnIn-process teaching
nnSafe for sterilization (SIP) and
cleaning (CIP)
CHECKING THE PRESENCE OF THE
CONTAINER FOR SECURE FILLING
To be able to fill milk products such as
yogurt or café latte in containers, the
container must first be detected. The
BUS ultrasonic sensor from Balluff de-
tects from above whether the container
is present. Only then is the product filled.
Features
nnCan be used are pressures of
up to 6 mbar
nnPTFE membrane provides
aggressive media protection
nnStainless steel housing
nnDigital display with direct
measurement value output
OBJECT DETECTION DURING
PRODUCTION
Hygienic regulations are especially
critical in the production of milk
products. Optical sensors for object
detection from Balluff meet the relevant
hygiene requirements. These rugged
sensors can be cleaned in-process
using any of the common procedures.
Aggressive media such as cleaning
agents have no effect on them.
Features
nnEcolab certified, EHEDG conformal,
FDA approved, in IP69K
nnBright, homogeneous light spot
for simple alignment
nnLong ranges and precise
object detection
nnAvailable in all optical function
principles
COLORED LABEL DETECTION
When detecting label colors, even the
slightest shades, they need to be
discriminated. This means the sensors
have to reliably detect faded colors
or differences in print quality. Our BFS
color sensor handles this with aplomb.
Features
nnGreatest precision
nnEspecially insensitive to ambient
light thanks to pulsed white light
nnIO-Link versions available
nnFiber optics for use in challenging
ambient conditions
More information about our solutions for packaging in dairy
processing can be found at www.balluff.com
VEHICLE DETECTION
The milk transport vehicles are equipped
with RFID tags. Now every transport
step can be tracked: from the laboratory
test to quality inspection to the pumps
moving milk from the vehicle tank to the
storage containers to cleaning of the
vehicle tank. This optimizes transport
and ensures reliability. Since the data
is transmitted directly, the time until the
laboratory confirms the inspection is
shortened for example. Information from
the laboratory about the milk quality,
transport time for the milk as well as the
tank cleaning process can be retrieved
at any time.
Features
nnReliable track-and-trace
nnAutomated logistics
18 | Food industry

Solutions
for meat processing

DETECTING THE PDF417 CODE

ON THE DELIVERED RAW PRODUCT

POSITION DETECTION
IN HYGIENIC AREAS

LEVEL CHECKING IN
THE MIXER/GRINDER
DETECTING THE PDF417 CODE ON
THE DELIVERED RAW PRODUCT
When the raw product is delivered it
must first be detected and identified.
This is done using so-called PDF417
codes located on the raw product.
Unfortunately, these codes are frequent-
ly not at the same height. Using the
portable reader BVS HS-P the codes
can still be read simply and flexibly.
Features
nnCommon 1D-, stacked and 2D
barcodes as well as direct marking
codes can be read quickly and reliably
nnRugged, industrial grade design
nnIP65 with drop protection up to 2 m
nnWork without fatigue thanks to low
weight and ergonomic shape
LEVEL CHECKING IN THE
MIXER/GRINDER
Continuous and errorless processing
requires that there always be sufficient-
meat in the grinder. Our BCS capacitive
sensors are ideal for level sensing in the
grinder.
Features
nnSmartLevel technology for
conductive media
nnEHEDG conformal, FDA approved,
in IP69K
POSITION DETECTION IN HYGIENIC
AREAS
In sausage production, meatpieces are
transported on conveyor belts. Trouble-
free processing means the position of
the pieces must be correct and missing
pieces need to be reliably detected.
At Balluff you will find a wide range of
optical stainless steelsensors that are
ideal for hygienic areas. They are extre-
mely rugged and can be cleaned using
all the common cleaning processes.
Features
nnEcolab certified, FDA approved, IP69K
nnAlloptical function principles available,
e.g. retro-reflective sensor, diffuse
sensor
nnEasy to install
nnWashdown design for ease of cleaning
More information about our solutions for
packaging in meat processing can be found
at www.balluff.com
 Pharmaceuticals | 21

Packaging in the pharmaceutical industry

ACT FLEXIBLY.
PRECISELY METERED

Pharmaceutical applications demand high reliability, compact enclosures,

minimal measuring tolerances, and the ability to flexibly integrate sensors
into a system. Along with these requirements come a variety of tasks.
From positioning to feeding to joining and marking to sealing liquid or solid
materials. At the same time the sensors need to handle many different
kinds of packaging including ampules, bottles, cans or blister packs.
With consistent quality of course.
22 | Pharmaceuticals

SEAL MONITORING

LEVEL DETECTION
 Solutions for
the pharmaceuticals industry

CHECKING THE BLISTER

PACK CONTENTS

PRECISE CUTTING AND

PUNCHING OF BLISTERS

DETECTING, COUNTING AND

PACKAGING TABLETS
24 | Pharmaceuticals
LEVEL DETECTION DETECTING, COUNTING AND
PACKAGING TABLETS
BCS capacitive sensors from Balluff Our BOH optical sensor head is a
reliably detect levels of various materials. modular system consisting of an emitter
Depending on the application type the and receiver. It allows you to individually
level can be detected non-contact or in adapt the distance and size of the
direct contact with the medium. downcomer. The tablets are reliably
detected and counted as they are
packaged in tins.
Features
nnSmartLevel technology for Features
conductive media
nnFast installation nnDistance
is freely selectable
nnGood adhesion compensation nnCompact design
nnCompensates for contamination
CHECKING THE BLISTER PACK
CONTENTS
When several monitoring functions are
required at the same time or in quick
succession, a BVS vision sensor from
Balluff is the right choice. It can be
flexibly adapted to your processes, and
changes can even be made in-process.
Therefore, all you need is a single sensor
to reliably monitor your production.
Features
nnRapid installation and configuration
ensure short setup times
nnConvenient setup
PRECISE CUTTING AND PUNCHING
OF BLISTERS
Contrast sensors ensure fast and secure
print mark detection. This is important,
among other things, for monitoring the
position of printing templates and syn-
chronizing cutting processes. This is
the only way you can cut and punch
precisely and maintain fast and safe
production with a high quality result.
Features
nnQuick, secure production
nnAdjusting possible during operation
nnVarious product series for versatility
nnHigh quality
nnReliable detection of any print mark
using different light colors
SEAL MONITORING
Filling involves monitoring the height and
diameters of bottles. This is done using
the high-resolution BLA light array. First,
the BLA detects the width of the bottle
neck and compares it with previously
taught-in values. Second, the correct
cap is selected. Then another light array
checks, based on the bottle height,
whether the cap is sitting flush on the
bottle.
Features
nnTeach up to six different objects
nnRugged metal housing for use in
harsh environments
nnIO-Link versions available
More information about our solutions for packaging can be found at
www.balluff.com
 Packaging industry | 27

Packaging

PREPARED FOR ANYTHING.

TAILOR-MADE AND EFFICIENT

PILLOW BAG AND CARDBOARD PACKAGING MACHINES

Pillow bag and cardboard packaging machines involve a large product variety, resulting in
the need for maximum flexibility. The machines product many different pillow and packaging
shapes. This is because constantly new packaging concepts need to grab consumers' attention.
The lot quantities become ever smaller and entail frequent format changes. They required
flexibility and speed are reliably achieved with Balluff products.

PALLETIZING AND DEPALLETIZING SYSTEMS

Palletizing and depalletizing of boxes and cartons demands absolute accuracy and great
flexibility. At the same time, the largest possible quantities need to be processed. Use the
professional support of Balluff. Whether for the reliable flow of material with track-and-trace,
the correct handling of different packages, or the reliable handling of the packaging material,
our sensors also ensure exact positioning for an uninterrupted packaging process.
28 | Packaging industry

Solutions for
pillow pouch machines

TRANSPARENT FILM
DETECTION

MONITORING THE DIAMETER

OF FILM ROLLS
WEB EDGE CONTROL

PRINT MARK DETECTION

ROLL GUIDING
30 | Packaging industry
ROLL GUIDING
Trouble-free packaging on the pillow bag
machine means ensuring that the roll
material is continually tensioned and
the correct length of film is always
maintained. An inclincation sensor from
Balluff assists in continual tensioning
by directly measuring the angle of the
dancer arm.
Features
nnNo additional target necessary:
direct tilt angle measurement
nnSimple installation and startup
nnGreater accuracy than comparable
solutions using an inductive sensor
nnNo mechanical correction – simple
teaching of the zero point on pin 4
TRANSPARENT FILM DETECTION WEB EDGE CONTROL
Our optical sensors reliably detects Our light array sensors measure the
the presence of transparent film in pillow edge position of fast-running foil or
bag packaging. woven bands. The determined values
can be used to precisely control the
drive and guides on your production
Features equipment. The result is even and
straight web running. Our sensor
nnVarious optical technologies are available in a number of different
nnBackground suppression versions. This allows you to respond
flexibly to any customer requirement.
Features
nnHigh linearity from especially even
light distribution
nnFor tight mounting conditions:
compact version in rugged fork-style
housing or with narrow emitter/recei-
ver strips and separate electronics
MONITORING THE DIAMETER OF
FILM ROLLS
To make sure depleted film rolls are
replaced in time, their diameter must be
continually monitored. The BOD photo-
electric distance sensors from Balluff are
ideal for this. They measure with extreme
precision, regardless of color, material
and degree of reflection of the foil.
Features
nnReduced downtimes thanks to precise
and stable measurements
nnIndependent of the film properties
nnFlexible use thanks to adjustable
measuring range
nnFast and easy mounting, teach
keys for setting
nnLong service life and reliable
functionality: rugged metal housing
PRINT MARK DETECTION
Reference and print marks help to
reliably detect packaging materials in
automated production processes and
to position them correctly. The BKT
contrast sensor from Balluff reliably
detects these reference marks.
Features
nnAdjusting possible during operation
nnIP67
nnHigh switching frequency ensures
a high fill rate
More information about our solutions for
pillow bag systems can be found at www.balluff.com
32 | Packaging industry

Solutions for
cardboard packaging machines

ACCESS CONTROL

CORRECT FEED OF
THE BLISTER STACK
FORMAT ADJUSTMENT

CODE AND PLAIN TEXT DETECTION

ON PACKAGING
34 | Packaging industry
ACCESS CONTROL
With industrial RFID systems you restrict
access to machines for safety and to
prevent tampering. Distinguishing bet-
ween persons enables limited access to
certain screens. The views for the inter-
face can be automatically changed.
Access control allows operator working
times to be viewed and regular main-
tenance to be performed.
Features
nnReliable reading with 3 mm thick
stainless steel wall on 125 kHz
RFID antenna
nnColor coded key pendants for
various user roles
More information about our solutions for cardboard packaging machines
can be found at www.balluff.com
FORMAT ADJUSTMENT
Packaging is playing an increasingly
large role in purchasing decisions.
They are often even the only differentia-
ting feature versus the competition,
so that the variety of shapes and sizes
is increasing. Balluff‘s magnetostrictive
linear position sensors simplifies the
measuring and storing of shape data,
makes fast and reliable format changes
possible, and thereby increase the yield
rate.
Features
nnProduction reliability thanks
to automated format changing
nnReduced setup times
CORRECT FEED OF THE BLISTER
STACK
Blister packs filled with tablets are
packed in boxes precisely portioned.
This means they have to be fed with
exact precision. Our BMF magnetic
sensors monitor the position of the
pneumatic grippers on the machine,
thereby preventing deviations.
Features
nnPrecise positioning
nnCorrect feeding
nnHigh flexibility
nnAvailable for any T- or C-slot
CODE AND PLAIN TEXT DETECTION
ON PACKAGING

Of relevance to quality assurance at

the end of the packaging process is
checking plain text on the packaging
and verifying the printed barcode.
Manufacturing and expiration dates as
well as serial numbers need to be
quickly and reliably verified. BVS vision
solutions from Balluff are the right ans-
wer for a wide variety of applications in
image processing.

Features

nnRead, check and verify codes

and text in one step
nnFlexible, targeted linking to
the production environment
nnSmartCamera available as
IO-Link or fieldbus version
nnComplete imaging and analysis
in one product
nnStandardized C-mount lenses
and M12 connectors
36 | Packaging industry

VERIFYING STACK HEIGHT ON EXACT POSITIONING OF STRETCH

THE PALLET FILMS

The BOD photoelectric distance sensors
check pallet heights with extraordinary
accuracy. Even over longer distances.
The sensor is versatile thanks to settable
measuring ranges and flexible for use
with different pallet heights.
When wrapping the product with stretch
film, conserving material is key. This
means the stretch film must be precisely
positioned. Our BML magnetic encoder
is the ideal solution.

Features
Features
nnSimple to use, wear-free, non-contact
nnReliable regardless of material or nnSpace-saving and easy to integrate
surface properties thanks to compact form factor
nnParameterization and diagnostics
functions via IO-Link
nnSimple, intuitive operation
with keys and display
nnMaximum protection with
Laser Class 1
nnLong service life thanks to rugged
housing with higher enclosure ratings

More information about our solutions for palletizing and depalletizing

machines can be found at www.balluff.com
Solutions for palletizing
and depalletizing machines

VERIFYING STACK HEIGHT

ON THE PALLET
PRECISION POSITIONING
OF STRETCH FILMS
38 | Packaging

INNOVATIVE SOLUTIONS
FOR ALL REQUIREMENTS.
40 | Packaging
Application
BOTTLING EQUIPMENT
Level detection in storage
tanks
Level monitoring for
bottling
Seal monitoring
Label detection on
beverage bottles
Detecting liquid in
transparent bottles
DAIRY EQUIPMENT
Level detection in a yogurt
tank
Object detection during
production
Colored label detection
Checking the presence
of the container for secure
filling
Vehicle identification
PACKAGING EQUIPMENT FOR MEAT PROCESSING
Detecting the PDF417
code on the delivered
raw product
Level checking in the
mixer/grinder
Position detection in
hygienic areas
PACKAGING EQUIPMENT FOR THE PHARMACEUTICAL INDUSTRY
Level detection
Packaging pills into
bottles
Checking the blister pack
contents
Precise cutting and
punching of blisters
Seal monitoring
Product family Example product Housing material Functions, interfaces, properties
Pressure Sensors BSP …-ZT006- Stainless steel IP67, Triclamp process fitting, 7-segment
BSP A02S1B-S4-006 1.4301 LED display
BTL magnetostrictive BTL5-E17-…-SF-… Stainless steel FDA conformal ad Ecolab certified, IP69K,
positioning system, 1.4404 analog output 4… 20 mA, temperatures
SF level sensor up to 130 °C (1 h)
Vision Sensor BVS BVS ID-3-005-E Cast aluminum, ABS IP54
Photoelectric BOH FR-Z007-01- Aluminum IP65, red light LED
Sensors S49F
Through-beam fork BGL A Metal IP67, red light, PinPoint, infrared, laser,
sensor BGL fluid detection, transparent material
detection
BGL C Metal IP67, IO-Link version, red light
Stainless steel fork BGL004L, BGL004M, Stainless steel IP67, IP69K, active surface PMMA,
sensor BGL BGL004N, BGL004P 1.4404 through-beam
Capacitive immersion BCS S04K501-…- Stainless steel IP68, 10 bar/IP69K, autoclave safe,
sensor BCS S04G-T50 1.4404 EHEDG-conformal, active surface PEEK
BOS photoelectric BOS G18E-PA-…-S4 Stainless steel Ecolab certified, IP69K, IP68, smooth tube
sensor 1.4404
BOS R01E-…-K_20- Stainless steel Ecolab certified, IP67, IP69K,
00,2-S49 1.4404 optical surface PA
Through-beam fork BGL004L, BGL004M, Stainless steel IP67/IP69K, active surface PMMA,
sensor BGL BGL004N, BGL004P 1.4404 through-beam
Color sensor BFS BFS000L Metal IP54, white light, fiber optics, cable
Ultrasonic sensor BUS M30E2 Stainless 1.4571, IP67
BUS PBT, TPU
Industrial RFID BIS U-620-…-101- Aluminum IP65 with connectors, RS 232 interface,
Systems BIS U …-… ambient temperature –20…+50 °C
Portable reader BVS BVS HS-P IP65, drop protection > 50 drops,
2 m on concrete
Capacitive sensors BCS0086, BCS0087, PVC, PTFE, PBT SmartLevel15, IP64
BCS BCS0088, BCS0089
BCS S04K501-…- Stainless steel IP68, 10 bar/IP69K, autoclave safe,
S04G-T50 1.4404 EHEDG-conformal, active surface PEEK
BOS photoelectric BOS G18E-PA-…-S4 Stainless steel Ecolab certified, IP69K, IP68, smooth tube
sensor 1.4404
BOS R01E-…-K_20- Stainless steel Ecolab certified, IP67, IP69K,
00,2-S49 1.4404 optical surface PA
Through-beam fork BGL004L, BGL004M, Stainless steel IP67/IP69K, active surface PMMA,
sensor BGL BGL004N, BGL004P 1.4404 through-beam
Capacitive sensors BCS M_TT_2-...-AT02 PTFE IP64
BCS
BCS D50TT_-…-ET02 PTFE IP67
Optical head BOH BOH AR-R… Aluminum IP65, through-beam, Red light LED,
active surface PMMA
Vision Sensor BVS BVS ID-3-005-E Cast aluminum, ABS IP54
Contrast sensor BKT BKT 67M-…-U-S92 Metal IP67, red, green and blue light,
interchangeable lenses
Light array BLA BLA 50A-001-S115 Aluminum IP65, through-beam,
laser red light
Application Product family Example product Housing material Functions, interfaces, properties

PILLOW POUCH MACHINES

Roll guiding
Transparent film detection
Web edge control
Monitoring the diameter of
film rolls
Print mark detection
Inclination sensor BSI BSI Q41K0-_B-M_ Plastic IP67, angle range + 45°… – 45°, measu-
S045-S92 ring principle MEMS, resolution 0.09°
Photoelectric BGL 80A-009-S49 Die-cast zinc IP67, transparent material detection,
Sensors laser red light
BOS 6K-PU-PT10-… ABS IP67, retro-reflective, red light LED,
active surface PMMA
Fork sensor BGL BGL 50C-...-S4 Aluminum IP67, through-beam, red light LED,
light array
Laser light array BLA BLA 50A-001-S115 Aluminum IP65, through-beam, laser red light,
(BLA0001) light array
Micromote light array BOH AR-...-...-01- Aluminum IP65, through-beam, optical sensor head,
S49F red light LED, light array
Photoelectric distan- BOD 21M-…-S92 Die-case zinc, IP67, laser red light
ce sensor BOD aluminum
Contrast sensor BKT BKT 67M-…-U-S92 Metal IP67, red, green and blue light,
interchangeable lenses

CARDBOARD PACKAGING MACHINES

Correct feed of the blister Magnetic cylinder BMF 235K-PO-C-2A- PA 12 IP67, T-slot
stack sensors BMF SA2-S49-00,3
Format adjustment BML magnetic BML-S1F Aluminum IP67
encoder
BML-S1G Die-cast zinc IP67
Nickel and chrome
plated
BML-SL1 IP67
BML-S2B PBT IP67
Magnetostrictive BTL6 U110-M_-PF-S4 Aluminum IP67, IO-Link
positioning system
BTL
Access control Industrial RFID BIS L-404-035-001- ABS IP67, round antenna, installation in
systems BIS L 00-S115 steel with clear zone
BIS L-204-03/L-… ABS IP67, ambient temperature
– 40…+ 85 °C
Code and plain text Vision Sensor BVS BVS SC- Painted aluminum IP67, interface
detection on packaging M1280Z00-…-000 LAN (Gigabit Ethernet)
BVS ID-3-…-E Cast aluminum, ABS IP54, red light LED

PALLETIZING AND DEPALLETIZING SYSTEMS

Verifying stack height on Photoelectric BOD 23K-…-S92 ABS IP69K, laser red light, active
the pallet distance sensor BOD surface PMMA
Exact positioning of BML magnetic BML-S1F Aluminum IP67
stretch films encoder
BML-SL1 IP67

More information about our solutions for packaging machines

can be found at www.balluff.com
42 | Industry 4.0

INDUSTRY 4.0 –
A REVOLUTION FOR
PACKAGING AS WELL.

Are you ready for the fourth industrial revolution? The availability of
relevant data in realtime as well as its linking – from production to IT to
the corporate management level – are the prerequisite for the optimal
value creation flow of your customers. Industry 4.0 assists them on the
road to more efficient machines, economical lot size 1, more food safety
and intelligent packaging.

We are completely dedicated to the development and manufacturing of

innovative sensors, identification, and network solutions. We ensure the
acquisition, transport, interpretation and provision of important data.

Together with our expert consulting and service this makes us the
preferred partner and enabler for Industry 4.0. We provide you with
assistance for the conception, development and realization of individual
solutions in the most varied industrial sectors.

Through these advanced concepts, we increase the efficiency and

profitability of your processes, making you more competitive.
And ensuring the competitiveness of your customers as well.

More information about our solutions for

Industry 4.0 can be found at www.balluff.com
44 | Industry 4.0

APPLICATIONS
FOR PACKAGING
MACHINES
WE ARE
4.0-READY

More efficient machines

APPLICATION: CONDITION MONITORING

Noise-free and efficient operation and thereby optimized

availability of your equipment is ensured by the high-
performance power supplies from Balluff. Our integrated
status indicator and the stress indication signal let you
know reliably and in time when the unit needs to be
replaced.

APPLICATION: PREDICTIVE MAINTENANCE

Prevent machine failures and downtimes. With our

optical sensors for example, which use IO-Link to report
contamination so you know when to clean or replace.
Food Safety

APPLICATION: TRACEABILITY APPLICATION: QUALITY ASSURANCE

Once information is acquired you can track it consistently –
with our industrial RFID systems. You have the overview
of access to devices and how often they were cleaned,
where a product is coming from and where it is now, which
tools are currently needed and – especially for the process
industry – which recipe should be used.
Early detection of errors or foreign objects in products
and sorting out bad parts is an important aspect of
quality assurance in the food, beverage and packaging
industry. Our vision sensors will help you.

Economical lot size 1

APPLICATION: RECIPE CHANGES

Achieve greater production flexibility using

RFID as data storage directly on the product.

APPLICATION: FORMAT CHANGES

The simple modification of your machines for different

packaging formats is made possible using our BTL
magnetostrictive linear position sensor in the rod or profile
style housing with realtime Ethernet. These transducers
measure the absolute position and speed with speed and
precision.
46 | Industry 4.0

EFFICIENTLY NETWORKED.
VIA IO-LINK.
The bi-directional communication interface IO-Link is a veritable enabler technology
for the Smart Factory. A standard that we have developed together with our partners.

With IO-Link, you communicate from the control unit down to the lowest level of
automation through a universally applicable interface. Even at high data volumes,
the fieldbus-neutral point-to-point connection transmits signals and data safely and
reliably over a simple three-wire cable. In this way we make efficient, transparent
and demand-based production processes in your company possible.

Application example: Monitoring

the tank level

The food and beverage industries often

use stainless steel tanks that are not
accessible. A system consisting of a
high-quality sensor with IO-Link interface
and the SmartLight LED signal tower
light brings clarity.
SENSOR
IP69 network and IO-Link blocks in stainless
steel housing

The new family of network modules was

developed for the extreme conditions of
the foods and pharmaceuticals indus-
tries. Corrosion and cleaning agent
resistant and with easy to clean wash-
down design, they ensure safe and
errorless signal transmission. Even in
challenging environments with large
runs.

SmartLight for visualizing the tank level

Balluff SmartLight machine lights permit

simple visualization of the tank contents.
The are also highly visible at great
distances, offer individually definable
colors and mode changes on-the-fly.

SENSOR

More information about our solutions for Industry 4.0

can be found at www.balluff.com
 SAFETY
OVER
IO-LINK

Simply safe
Automation demands safety. With Safety over IO-Link from Balluff you enjoy
the proven benefits of IO-Link now for the safety of people and equipment as
well. By linking automation technology and safety technology, you get full
machine security in one system. IO-Link communicates down to the last meter
and provides both sensor/actuator details as well as safety information.

With Balluff smart safety you reliably secure your modular packaging lines.
Our Safety-Hub is simple to integrate, responds fast and can replace the control
cabinet.

Safety I/O module (Safety-Hub)

The new safety I/O module is simply

connected to the IO-Link master. Since
the system is open all the way to the
FIELDBUS
sensor level, you can connect nearly any
WITH IO-LINK
safety device. Parameters are configured
INTERFACE
centrally using the controller. Safety-
related information is sent directly
through the master to the controller.

Safety components

In addition to the Safety-Hub, Balluff

offers other products for safety technol-
ogy. Emergency-stop devices, light
curtains, and safety switches are used to
SAFETY make packaging machines safe. With
OVER Balluff safety products you meet prevai-
IO-LINK ling safety requirements economically.
DEVICES

SAFETY
SENSORS/
ACTUATORS
 Balluff | 49

Balluff

WE OPEN
NEW VISTAS.

Balluff is one of the leading suppliers of high-quality sensor, identification and network
solutions for your automation requirements. Family-owned and led for more than 90
years, around 3200 employees in 61 subsidiaries and representatives as well as nine
production facilities around the world represent the highest quality standards. So that
you always get the best.

For innovative solutions that increase your competitive ability using our top products
and services. Through long years of experience, the expertise of a manufacturer and
high personal dedication.

In line with our motto "Innovating Automation" we are pacemakers of automation,

improvers and new developers, and technological trailblazers. In open exchange with
trade associations, universities and research facilities as well as in close contact
with our customers we create new industry solutions or a new communication stan-
dard such as IO-Link. Innovative Balluff solutions equip you for a successful future.

We have the future firmly in view. In everything we do. With sophisticated environ-
mental management we protect the environment and handle our resources with care.
This also creates for you the best prerequisites for sustained action.

We keep our promises. Because you can always rely on us, our products and our
adherence to delivery dates and schedules. All in the name of mutually beneficial
partnership.
 Packaging | 51

REFERENCES.

The demands in packaging are high and getting higher. Our complete commitment is
to the success of our customers. Future-looking technologies, market-oriented solu-
tions and the expertise of an experienced manufacturer are what we draw on to in-
crease your competitiveness. This is why companies worldwide trust in Balluff solu-
tions for packaging systems.

We work together with such companies as

Germany
Headquarters
Balluff GmbH

balluff@balluff.de
Fax +49 7158 5010
Schurwaldstrasse 9

Phone +49 7158 173-0

73765 Neuhausen a. d. F.
US
HOW TO
CONTACT

www.balluff.com
Doc.-No. 816061/Mat.-No. 118302 EN · A17; Subject to modification. Replaces F13. Photo credits: The illustrations on pages 1, 2, 3, 4, 5, 6, 26, 50 and 52 were used with the kind permission of Krones AG.