Doc.

ID: OMAC PackSpec

PackSpec Template – End User
Rev. 2.2
3 October-2018

Background

PackSpec is an effort to standardize the process of equipment acquisition, from the initial request for
quotation to final factory sign-off, thereby clarifying the expectations of both machine builder and end
user. The underlying premises are that the focus of this process should be on machine function,
performance and testing, and that machine quality will improve as unnecessary design constraints are
reduced.

The OMAC PackSpec Template is intended to provide a standardized framework or outline for the
specification of automation machinery. It is an extension of the OpX Leadership Network’s Request
for Proposals (RFP) Guidelines for the CPG Industry and companion RFP template, specifically
aimed at packaging equipment and its associated automation requirements. Its basic goals are
twofold:

 focus the specification process on machine performance;

 help end-users and machine builders leverage PackML and the associated OMAC
technologies.

The OMAC PackSpec Template is divided into two distinct documents. The first gives an outline of a
machine specification from the point of view of the end-user or purchaser. A document based on this
section would describe who the purchaser is, and what he or she is interested in purchasing – think
Request for Quotation or Request for Proposal. This section would apply in particular (but not
exclusively) to the end-user interested in purchasing a unique machine from a custom or semi-
custom machine builder. This document is developed from this perspective.

The second document follows a similar outline, but takes the opposite view, namely that of the
machine builder or seller. A document following this outline would describe the seller and specify the
machine being sold. This section would apply in particular to a machine builder producing a standard
set of equipment offerings. In such cases it might make sense to for a machine builder to have a
standard response to a request for quotation. The outline could also be the basis for a core part of a
machine’s functional specification.

Harmonizing the expectations of the purchaser with the specifications of the seller is one of the key
aspects in the process of equipment acquisition. By providing document structures to both end-user
and machine builder, we hope to facilitate this harmonization process.

We offer some general suggestions when implementing these outlines.

 Avoid vague language. Use quantifiable rather than qualitative terms. Terms like “quiet” or
“smooth” or “fast” will be interpreted differently by various parties and are often effectively
meaningless. Instead define, for example, maximum allowable decibel levels, surface
roughness specifications or machine speeds in measurable quantities.
 Wherever possible refer to accepted industry standards and/ or specific measurement
techniques.
 Concentrate on critical requirements.
 Develop the machine requirements or specifications in such a way that they are easily tested
or verified.

The following outlines are meant to be a suggested basis for creating machine specifications. Not all
sections will apply to all machine types; many machines will require additional sections or sub-sections
not covered here.

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As indicated, PackSpec is an extension of the Request for Proposal work product produced by the
OpX Leadership Network convened by PMMI, the association for packaging and processing
technologies. These two work products are intended to be used together in the specification of
packaging machinery. The Request for Proposal work product is divided into seven distinct sections,
as outlined in the graphic below. PackSpec follows this same structure. Individual sections
throughout this tool are identifiable by the associated heading from this graphic.

Copyright © 2018. OMAC. This publication was developed through OMAC. It may be downloaded,
reproduced, and distributed for business or academic use, but not for license or sale, provided there is
clear attribution to OMAC as the developer and copyright owner. OMAC accepts no legal
responsibility for the use of this document by third parties.

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REVISION HISTORY

Revision Date Author Description

0.1 09-Dec-2011 PackSpec workgroup Initial draft

0.3 01-Jul-2012 T. Jensen Straw Man Feedback

0.4 02-Oct-2012 Workgroup General additions
0.5 23-Oct-2012 C. Bostrom Division of document into OEM, EU
portions. Expanded introduction
section. Added PackML
implementation recommendations.
0.6 04-Dec-2012 Workgroup Review
0.7 05-Dec-2012 C. Bostrom, M. Wolf Finalize mark-up as suggested by v0.6
0.8 21-May-2013 Workgroup General Review
0.9 --- --- ---
1.0 02-Jun-2013 Workgroup Release
1.1 26-Jul-2016 T. Doney Changes/enhancements agreed upon
in the Workgroup meeting held in 2015
Separation to PackSpec End User
1.2 24-Aug-2016 Workgroup Incorporate changes before submitting
to OpX RFP Task Force
2.0 25-Oct-2016 T. Doney Handover to OpX RFP Task Force
2.1 13-Aug-2018 T. Doney Renumber to align with OpX RFP
(Proposed) Process Template
2.2 03-Oct-2018 T. Doney Incorporated OpX RFP Heading
Graphics

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Section A: Specification Template for End Users

In the introduction the end-user should introduce his or her company and give a general overview of
the project being proposed. Be sure to review the legal aspects of this section with appropriate
counsel.

1.1 Provide description of end-user or purchaser. Describe the end-user's general mission
and where it is headquartered. General commercial information may also be included.
1.2 Provide overview of equipment’s purpose and end-user’s general requirements.
1.3 Describe the author and provide details regarding the author’s authority to purchase
capital equipment on behalf of end-user.
1.4 Define legal terms and conditions.
1.5 Reference or describe the document that will define conditions for machine acceptance.
1.6 If known and applicable, give the location of the final machine installation
1.7 Document approval process. List the names and titles of persons authorized to approve
changes to the specification.
1.8 Document revision history

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Not Used

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Not Used

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Documents Summary

4.1. Not Used

4.2. Factory Acceptance Test (FAT)

4.2.1.Apply the Factory Acceptance Test Checklist developed by OpX – link:

http://opxleadershipnetwork.org/factory-acceptance-tests/download/factory-acceptance-
tests-checklist

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Project Introduction – Equipment

5.1. Manufacturing Overview

5.1.1.What is upstream of the machine? Supplier ( is / is not ) responsible for the conveyor
transition to the machine in feed.
5.1.2.What is downstream of the machine? Supplier ( is / is not ) responsible for the conveyor
transition from the machine discharge.

5.2. Project Management Procedures - Schedule and Testing

5.2.1. Produce Gantt chart describing expected project timeline. Remember that most
builders will not begin work on a project until certain commercial obligations on the
part of the end-user have been met. Allow for changes to the timeline accordingly.
5.2.2. Describe general expectations with regard to factory acceptance testing (FAT). Refer
to and apply the OpX Leadership Network’s FAT Checklist – link:
http://opxleadershipnetwork.org/factory-acceptance-tests/download/factory-
acceptance-tests-checklist
5.2.3. Provide a listing of the test materials that must be available to execute both pre-FAT
testing as well as the FAT itself
5.2.4. Provide instructions for the disposal of the FAT materials once the tests are
completed.
5.2.5. Name any third-parties that will be used to evaluate machine performance.
5.2.6. Describe any induced failure or stress testing that must be performed prior to
acceptance.
5.2.7. Describe general expectations with regard to site acceptance testing. Name the party
who will produce the relevant test protocols and describe the approval process.

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5.3. Machine Design

5.3.1.Machine Design - Hygienic and Mechanical Minimum Requirements
This section specifies the minimum requirements and engineering best practices for hygienic
construction and mechanical design.
5.3.1.1.
Basic Hygienic Principles – a machine installed in a food manufacturing facility
must be properly designed. The fundamental design must eliminate or minimize
all hallow cavities, cracks, crevices, ledges, and other places that are difficult or
impossible to clean. The machine design should ensure that
 Specific hygiene requirements for the product being run are met
 Allow for easy cleaning and inspection of all machine surfaces
 All surfaces should be designed to eliminate product collection or liquid
pooling and must be self-draining
 Cooling water, drain lines, and drip pans must be piped and/or directed to a
drain
5.3.1.2. Hollow Bodies – No hollow body shall be used on machine parts having direct
food contact.
 On other machine parts using hollow bodies should be avoided
5.3.1.3. Glass – no glass shall be used in any part or component of the machine
5.3.1.4. Wood – Wood is not allowed in any part or component of the machine.
5.3.1.5. Surfaces – horizontal or flat surfaces should be avoided, since dust can
accumulate. All surfaces should be angled.
5.3.1.6. Welding – All welding should be
 Lead free
 Smooth and free of voids, pinholes, cracks, splatter, etc.
 All welds must be passivated
5.3.1.7. Floor Clearance
 To insure adequate cleaning and inspection, the entire machine shall have a
ground clearance of at least XXX mm.
 To insure safety, the entire machine shall have a ground clearance no higher
than XXX mm.
5.3.1.8. Wall Clearance – If a machine or part of the machine is wall mounted, a
minimum distance of XXX mm is required between the machine and a wall to
allow for easy access for cleaning and inspection
5.3.1.9. Steel Quality and Finish – all steel parts and weldments in contact with product
must be
 Made with 304L stainless steel with an appropriate finish
 Stainless steel, machined, and bearing surfaces shall not be painted
5.3.1.10. Machine Frame Design – Open frames are preferred for better visibility,
cleanability, and sanitation. No extra holes should be drilled as they make
cleaning impossible.
 Profile channels shall not be used since they cannot be cleaned.
5.3.1.11. Design of Guards – all guards shall allow the operator to observe, inspect, and
monitor the machine’s operation and condition. Materials used for guarding
should
 Resist the cleaning procedure in place in the factory
 Be scratch resistant when dry cleaned
 Guarantee visibility for the life of the machine
5.3.1.12. The machine shall not have any sharp point or edges. If such surface are
required, they must be guarded.

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5.3.1.13. Design of Components – Any component in excess of 10 kg which is required to

be periodically removed shall be equipped with lifting eyes and shall be identified
in the proposal stage.
5.3.1.14. Fasteners: Nuts, bolts, screws
 Machine design shall minimize the use of fasteners
 When needed, fasteners should not have exposed threads and will have a
positive locking means
 All fasteners should be made of stainless steel
5.3.1.15. Bearings, Motors, Gearboxes, Chains
 Bearings, motors, gearboxes, and chains should be mounted outside the
product areas
 Bearings should be sealed for life with food grade (H1) lubricant and free of
grease fittings
5.3.1.16. Hoses – All hoses and their support assemblies should be
 Easily accessible and designed to be easily removable for maintenance,
cleaning, and changeovers
 All hoses should be transparent and the interior surfaces must meet product
contact surface guidelines.
 All hoses should be labeled with maximum pressure rating and termination
information.
5.3.1.17. Pneumatics
 Supplier shall provide a filter and regulator to the machine. A lockable dump
valve is required which should operate automatically on an Emergency Stop
 All air manifolds will contain a pressure gauge to show active pressure in the
manifold
 A sensor is required to detect low pressure conditions in the machine’s main
supply line.
5.3.1.18. Maintainability
 The machine shall be delivered with a checklist that contains 3 types of tasks
5.3.1.18.1. Cleaning with instructions for the proper tools, cleaning detergents,
method, frequency and duration
5.3.1.18.2. Inspection – areas of inspection must be visible and easy to reach
5.3.1.18.3. Lubrication – design should permit safe lubrication with the machine
running. The lubrication plan should include illustrations of the point of
lubrication and the frequency
 Lubrication
5.3.1.18.4. Greasing locations should be clearly marked and labeled
5.3.1.18.5. Lubricants cannot come into direct or indirect contact with products or
packages
5.3.1.18.6. Only food grade lubricants registered with NSF as H1 can be used
5.3.1.19. Cleanability
 Construction of the machine must meet the GMP definition of ‘adequately
cleanable’ [21CFR110.40].
 Avoid “hard to reach” places
5.3.1.20. Water usage / quality
 Water type (de-ionized water for injection, etc.)
 Total usage
 Steam quality
 Pressure, temperature
5.3.1.21. Describe other utilities that must be supplied by the OEM
 Gas inputs (Nitrogen, natural gas, etc.)
 Vacuum

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5.3.2. Machine Design - Safety and Health Minimum Requirements

This section specifies the minimum safety and health requirements for machines to prevent injuries
and illnesses during installation, commissioning, startup, and operation in production plus
maintenance.

5.3.2.1. Machine must comply with all relevant European or US Safety and Health
machine directives and standards. Machine must also comply with local safety
and health requirements and machine standards.
5.3.2.2. The machine supplier must perform a risk assessment which details all the
hazards associated with the machine including
 Mechanical hazards
 Electrical hazards
 Noise
 Ergonomics
 Hot and cold surfaces
 Pressurized systems
 Explosive atmospheres
5.3.2.3. Risk Reduction – After the assessment, the following risk reduction hierarchy
must be followed
 Elimination of hazards
 Limiting exposure to the hazards by limiting the need for interventions
 Safe-guarding and Other protective measures – guards and other
protective devices must be provided to protect the operators when
safe design alone cannot reduce the risk
 Information for Use – Provide warning signs, audio and visual signals,
personal protective equipment (PPE), training, and safe operating
procedures must be provided.
5.3.2.4. Safeguards – Guarding must achieve “zero access” – making it physically
impossible to access hazardous parts of the machine without using a tool, key,
or password to remove or disable safeguards. The guarding must also
 Minimize interference with operator activities during operation and
maintenance
 Not be easily bypasses or rendered non-operational
 Be sufficiently robust to avoid damage during normal operation
 Be designed to prevent an operator from being able to reach a danger
zone before the machine comes to a complete stop.
 Allow routine adjustments, lubrication, and maintenance to be carried
out without having to remove them or open them.
5.3.2.5. Minimum safe distances – Openings – Guards must comply with ISO 13857 or
current applicable standard.
5.3.2.6. Fixed Guards – Design and installation must comply with ISO 14120 or current
applicable standard.
5.3.2.7. Movable Guards must
 Remain fixed to the machine when open if possible
 Be interlocked (with guard locking when needed to allow for a full stop
and the removal of all hazardous energy
5.3.2.8. Interlocked guards must be designed and installed such that the safety interlock
device and safety control system isolates power to all sources of hazardous
energy. They must be “fail safe” – a single failure in the safety system stops the
machine.
 When an interlocked guard is open the machine cannot operate

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 When the interlocked guard is opened during operation, the machine

must stop
 When the guard is reclosed, the energy can be restored but the
machine shall not restart by itself
 Restarting the machine will require a reset and restart by the operator.
5.3.2.9. When an operator is able to fully enter the machine, there must be Safety Rated
presence sensing devices provided such as
 Light curtains
 Pressure sensitive mats
 Scanning devices, such as laser scanners
5.3.2.10. Intervention Modes – operation and maintenance tasks must align with the
following intervention mode scheme
 Mode 0: Zero access – wherever possible, the machine should operate
with the need for intervening inside the machine
 Mode 1: Routing interventions shall be performed through interlocked
guards
 Mode 2: If an intervention requires working inside an interlocked guard,
there must be an additional locking device to prevent a reset/restart
while the operator is inside.
 Mode 3: Interventions requiring disassembly of the guards are to be
minimized. When they are necessary, they must be done under a Lock-
Out / Tag-Out procedure.
 Mode 4: Interventions where hazardous energy is required are not
allowed for routing operation or maintenance.
5.3.2.11. Energy Isolation (Lock-Out / Tag-out) – Devices capable of securely isolating
and releasing all hazardous energy sources (electrical, pneumatic, thermal,
hydraulic, etc.) must be provided. These isolation devices must be
 Grouped together
 Designed to engage a LOTO in less than one minute.
 Clearly labeled as to the function and whether the status is ON or OFF.
 Be lockable with a padlock
 Be activated only through direct mechanical action.
 Achieve a zero energy state.
5.3.2.12. The supplier must provide written Lock-Out / Tag-Out procedures that identify
the LOTO point locations. The procedure must identify the interventions for
which LOTO is needed.
5.3.2.13. Power Failure – the supplier must take into consideration the safety aspects of
machine operation when a power failure occurs.

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5.3.3. Machine Design - Electrical and Automation Minimum Requirements

This section provides the minimum requirements for the electrical and automation installation for
packaging machinery. Apply latest standards where applicable.
5.3.3.1. Control and Termination Panels – including the following:
 Local control panels
 Terminal/Termination panels
 I/O Panels
5.3.3.2. Panel Material and Construction – In dry environments, the panel must meet
IP54 (NEMA 12) requirements as a minimum. In wet environments, the panel
construction must meet IP65 (NEMA 4X), and HMI (Human Machine Interface)
panels shall be rated IP65 minimum.
 Each cabinet shall be provided with back panels for the mounting of devices.
 Provide an Ethernet network/data socket with associated wiring for network
access to PLC and I/O equipment installed in the panel.
 Panel locations must not interfere with operator access to equipment.
5.3.3.3. Supply Isolating/Disconnect Switch - For all power distribution panels, provide a
supply isolating/disconnect switch for each panel with a handle that can be
locked in the “OFF” (open) position, and with a position indicator for the “ON”
(closed) and “OFF” (open) positions. Provide the switch with a mechanical
interlock with the panel door to prevent opening the door when the switch is in
the “ON” (closed) position.
5.3.3.4. Overcurrent and Short Circuit Protection – all overcurrent and short circuit
protection devices must be sized based on the circuit load, and in accordance
with local standards.
5.3.3.5. Cooling and Heating – The temperature within the panel must be maintained
within limits per IEC 60204-1/NFPA or the current applicable standard. If the
temperature cannot be maintained naturally, then heating, cooling, and/or
ventilation to maintain the temperature. Vortex coolers are not permitted.
5.3.3.6. Lighting – Provide a lighting fixture at the top of the interior of reach section of all
freestanding/floor mounted enclosures.
5.3.3.7. Wiring and Cable Management – Where there are no locally adopted regulations
or standards, conductors must be sized in accordance with IEC 60204-1, IEC
60364-4-52 and/or IFPA70 or the current applicable standard.
5.3.3.8. Grounding Requirements
 The electrical distribution scheme (5-wire or 4-wire) must conform to local
regulations. Supplier to validate scheme if not specified elsewhere.
 Protective grounding conductors shall be sized in accordance with local
regulations.
5.3.3.9. Cable Tray and Conduit Requirements
 All cable trays shall be mounted to not interfere with operation, maintenance,
or cleaning of the equipment.
 All conduits shall be mounted to not interfere with operation, maintenance, or
cleaning of the equipment.
5.3.3.10. Labeling and Identification Requirements
 Provide a nameplate attached to the control panel adjacent to each incoming
power supply with the following information
5.3.3.10.1. Name or Trade Mark of Supplier
5.3.3.10.2. Certification Marks (e.g. CE, UL, etc.)
5.3.3.10.3. Serial Number
5.3.3.10.4. Rated voltage, number of phases, and frequency
 Warning and Hazard Labels

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5.3.3.10.5. Provide an electrical hazard warning label on the front door of

each panel
5.3.3.10.6. Provide electrical hazard warning labels on removable guards and
covers for energized circuit parts.
5.3.3.11. Motors, Motor Control, and Variable Speed Drives (VSD’s)
 All conveyor motors and associated VSD’s shall be rated for the local
standard 3 phase utilization voltage.
 Motor overload protection must be provided for each motor starter
5.3.3.12. Control Pushbutton Requirements (Suggested)
 Start button color shall always be green
 Stop button color shall always be red
 E-Stop button shall always be red and maintain a pressed position when
activated. Operator must pull button out and then press the Fault reset button
 Fault reset button shall always be blue with and integral lamp that can be
continuously illuminated or blinking. Energy shall not be restored to the
machine until the Fault Reset button is pressed.
 Machine operation shall not resume until the Start button is pressed after the
Fault Reset has occurred.
 Mechanical buttons shall be used
5.3.3.13. Communication and Programming Requirements
 Provide a fully documented PLC program (rungs, addresses, tags, etc.)
including comments and descriptions
 All machine I/O points shall match the device terminals on the schematics
 Alarm Management – the active alarm and history list must display all active
and actionable alarms for the equipment.
 All documentation shall be backed up on a flash drive and X hard copies shall
be provided.
5.3.3.14. Documentation
 Provide hard copies of electrical and pneumatic installation drawings. The
number of copies required shall be defined in the project specific requirements
section of the specification.
 The supplier wiring diagrams must provide details (field device identification,
field terminal number and wire number, etc.) related to the wiring of field
devices and panel mounted devices

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5.3.4.PackML Implementation – Use this section to define any requirements with respect to
required PackML modes, HMI screen formats, stack light configuration aligned with
machine states, etc. Additional information can be found in Section B.
 With reference to ISA TR88.00.02, define any general PackML support requirements.
Typically requirements could include support for plant-wide supervisory or
management systems or support for peer-to-peer communication. Specify data
transport methods and protocols. See additional information in Section B.
 The table below defines the portions of the PackML specification that are mandatory
for all machine implementations and those which are optional. Mandatory = Level 1
or Core Implementation
Mandatory + Optional = Level 2 or Full Implementation

TR88 / Specification Mandatory / Optional Supplier (OEM) Role

Section
States Mandatory To implement
Modes Mandatory To implement
Pack Tags Mandatory To implement
Light Tree Mandatory To implement
Push Buttons Mandatory To implement
Program Modularity Optional To be discussed with end
user
 Modes - A machine control mode determines the subset of states, state commands, and
state transitions that determine the strategy for carrying out a machine’s process. Refer to
TR88.002 for further information.
 States – In a machine state model, states are arranged in an ordered fashion that is
consistent with the specified operation of the machine. Refer to TR88.002 for further
information.
 PackTags – PackML PackTags provide a uniform naming standard for the PLC data
elements (tags) as well as data types, values, ranges, and where necessary data
structures to provide a comprehensive convention for communications between packaging
machines and to higher level systems such as MES. Refer to Section B of this document
and TR88.002 for further information.
 Light tree, sounder, and pushbutton standards- the following suggested light tree and
pushbutton configurations are not within the scope of ISA TR88.00.02. The configurations
are a result of the implementation of the standard.

5.3.4.1. Suggested Light Tree

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5.3.4.2. Suggested light states

5.3.4.3. For the audible alert, sound the buzzer or horn for 5 seconds as follows

Held (no production)

Unsuspending
Suspending

Suspended
Unholding
Resetting
Clearing

Stopping
Aborting

Holding
Stopped
Aborted

Execute
Starting

Machine States
Idle

Buzzer 5 sec F F F

5.3.4.4. Pushbutton standards (NFPA 79)

Held (no production)

Unsuspending
Suspending

Suspended
Unholding
Resetting
Clearing

Stopping
Aborting

Holding
Stopped
Aborted

Execute
Starting

Machine States
Idle

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5.3.4.5. Suggested Graphical templates Machine Control

5.3.4.6. Alarms and Events

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5.3.4.7. Safety View – contains the top view of the machine and highlights safety doors
and the E-Stop button(s). It is an illustrative screen within the Alarms & Events
screen group.

5.3.4.8. Production Summary – contains Key Production Data

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5.3.4.9. Format Parameter Settings – screen group that contains settings for each
recipe the machine operates in.

5.3.4.10. Diagnostics – this screen will show the active stop and provide the list of stops
and durations.

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5.3.4.11. Station and Manual – this screen allows an advanced operator or technician to
operate or jog individual parts of the machine.

5.3.5.Regulations (Local, National, International)

To the fullest extent possible, the end-user should specify build standards with regard to regulatory
compliance or certification. (Failure on the part of the end-user to provide adequate information here
does not necessarily release the machine builder from any legal obligations, however.)

5.3.5.1. Define any governing electrical regulatory bodies (CE, UL, etc.)
5.3.5.2. Define waste disposal obligations
5.3.5.3. Electrical wire color coding
5.3.5.4. USDA/FDA/FSMA
5.3.5.5. Cultural considerations (Kosher, Halal)
5.3.5.6. RoHS
5.3.5.7. Seismic or other environmental considerations
5.3.5.8. Other

5.4. Site Conditions (Environment where machine is being installed)

Provide mechanical layout drawings describing the installation site. Of particular importance here are
any site-specific details that would constrain the machine design.
5.4.1. Site Environment where machine is being installed
 Ambient Temperature
 % Relative Humidity
 Any Chemicals used in cleaning or process?
 Significant Dust Level?
 Required IP Rating for components and control enclosures
 Hazardous Environment?

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5.4.2.Provide plan view of the intended site of installation, including any necessary or
applicable information regarding upstream and downstream equipment.
5.4.3.Provide block diagram of the role and/ or function of the specified equipment within the
context of the overall line.
5.4.4.If applicable, define input and output run heights (i.e. conveyor heights).
5.4.5.Define maximum machine footprint and height requirements.
5.4.6. Define load bearing limits of floor at the installation location
5.4.7. Local Electrical Utility Requirements – Voltage and Frequency
5.4.8. Pneumatic Utilities
 Factory Air Supply pressure
 Factory Air Dryness
 Ability to maintain air pressure during instantaneous peaks in consumption

5.5. On Site Services Requirements - Machine Support

The end-user should define his or her expectations with regard to training and long-term machine
support. Possible considerations include:

5.5.1.Shipping and installation. In particular, the end-user must make known any special
constraints specific to the site of final installation that would affect the machine design.
Other possible considerations include:
 Certificate of Origin
 Shipping, hoisting and/ or lifting requirements
 Shipping containers and packaging – including wrapping to avoid
condensation during sea shipments
 Transportation methods
 Special size constraints – such as maximum available opening in building to
pass the machine through
5.5.2. Installation and Commissioning
 Expected role of supplier during installation
 Expected Role of Supplier during commissioning

5.5.3. Fault or Machine Support Response

 Terms of phone or online support
 Terms of field support
5.5.4.Training Needs
 Language for Training
 Training Agenda for Operators – Machine operation
 Training Agenda for mechanical and electrical technicians – Machine
maintenance
 Request permission to video record the training
 PMMI Certified trainer program or equivalent accreditation
 Can a changeover performed by the supplier technician as part of training be
videotaped?
 Training Documentation embedded in the HMI

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Project Requirements – Product and Package Description, Line Overview, Site Specific
Requirements

6.1. Product Description

 Suggestions for Powders Descriptions
6.1.1. Acceptable Breakage Rate
6.1.2. Free Flow Density
6.1.3. Dustiness
 Suggestions for product with solids / pieces Descriptions
6.1.4. Dimensions
6.1.5. Acceptable Breakage
 Suggestions for Liquids Descriptions
6.1.6. Viscosity
6.1.7. pH Level
6.2. Package Description
 Examples: Pouch, sachet, bottle, rigid tray, carton, case, shrink wrapped tray, shrink
wrapped bundle, pallet
 Dimensions
 If pouch, examples of features: gusset, spout, zipper
 If pouch, laminate description
 Label Description
 Gauge of paperboard and stiffness if carton
 If corrugate, memory at score lines and flute designation
 If pallet, load containment force needed & selected film’s maximum film pre-stretch %

Information regarding the mechanical characteristics of any primary or secondary packaging materials
must be conveyed to the machine builder. Because of the many possible machine configurations, the
list below is only intended to be suggestive; it is certainly not exhaustive and in many cases items
below will not apply to a given situation. Where possible the end-user should be prepared to supply
the machine builder with physical samples.

6.3. Package Material & Physical Characteristics

6.3.1. Package Material Physical characteristics

 Stiffness
 Surface roughness or coefficient of friction
 Weight
 Density
 Any characteristics that would affect selection of a sensor (optical characteristics, etc.)
 Any characteristics that would affect selection of a vision system (product graphics)
 Elasticity
 Viscosity
 Chemical/ environmental sensitivities
 Durability (Is product easily breakable?)

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6.3.2. Package Material Storage and Handling

 Refrigeration requirements
 Transportability (Is product freestanding? Is product easily conveyed?)
 Pressure vessel requirements (in the case of packaged liquids)
 Special feeding methods (augers, vibrator feeders, etc.)
 Maximum tensile, compressive or shear loads
 Chemical sensitivities (e.g. oxygen sensitive liquids)
 Any characteristics that would affect the selection of a robotic pick/ place tool.
 Amount of time needed for pre-conditioning at line before use

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Performance – Success Criteria

The end-user quantifies the machine requirements in detail here. It may be useful to provide a
description of any statistical tools used in evaluating the machine performance in an appropriate
appendix.

For evaluating total performance of a packaging machine, the end user should consult the guidelines
established by PMMI’s OpX Leadership network for Overall Equipment Effectiveness (OEE) – link:
http://opxleadershipnetwork.org/overall-equipment-effectiveness-oee/download/overall-equipment-
effectiveness-guidelines-cpg-industry

7.1. Quality Requirements

 If a filler, filling accuracy; if liquid, no foam
 If a labeling operation, specify no wrinkles, cutting accuracy, precision of alignment
 If a carton, tray or case, no extruding flaps, squareness
 If shrink wrapped bundle or tray, quality of shrink, balanced bulls-eye
 If a glue sealed package, fiber tear in the corrugate or paperboard

7.2. Performance Requirements

 Production Rate – Nominal and Maximum
 Efficiency % – per DIN standard
 Expected Changeover Time
 # of operators expected for production and changeover

7.2.1.Success criteria for final acceptance

 Efficiency per DIN standard over an agreed evaluation period
 Acceptable output quality level during an agreed upon evaluation period

7.3. Documentation - state the number of copies of manuals and control program documentation
required on the project
 Operation Manual
 Maintenance Manual
 Machine Control Program
 Spare parts, including list of components required for stocking
 Digital Copy and/or # of Hard Copies

8. Appendix

Add documentation and references as required.

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Section B: Additional Topics

1 PackTag Scope

The scope of support for PackTags must be agreed upon by the end-user and machine builder. For
example, if the end-user plans to manage recipes via a supervisory system, this must be specified in
detail. On the other hand, if the machine builder supports only a minimal subset of PackTags,
because of the simplicity of the machine in question, for example, this must be clearly communicated
to the end-user. Because of the potential impact on program architecture, it is recommended that
these issues be resolved early in the project rather than later.

ISA TR88.00.02 specifies only a minimal subset of PackTags required for PackML compliance. These
tags are listed below in the section titled Level 1 – Core. For reference, the full set of PackTags is
listed in the following section titled Level 2 – Full. Refer to OMAC’s PackML Implementation Guide
for further guidance on PackML implementation.

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Level 1: “Core”. The core approach aligns with TR88’s minimum tag set for information, machine
monitoring, and supervisory control.

Command Tags

Tag Path Type

UnitMode UnitName.Command.UnitMode Int32

UnitModeChangeRequest UnitName.Command.UnitModeChangeRequest Bool

MachSpeed UnitName.Command.MachSpeed Real

CntrlCmd Unitname.Command.CntlCmd Int32

CmdChangeRequest Unitname.Command.CmdChangeRequest Bool

Status Tags
Tag Path Type
UnitModeCurrent UnitName.Status.UnitModeCurrent Int32

StateCurrent UnitName.Status.StateCurrent Int32

MachSpeed UnitName.Status.MachSpeed Real

CurMachSpeed UnitName.Status.CurMachSpeed Real

EquipmentInterlock Unitname.Status.EquipmentInterlock Bool [2]

Blocked Unitname.Status.EquipmentInterlock.Blocked Bool

Starved Unitname.Status.EquipmentInterlock.Starved Bool

Admin Tags

ProdProcessedCount[#] Unitname.Admin.ProdProcessedCount[#].Count Int32

Count
ProdDefectiveCount[#] Unitname.Admin.ProdDefectiveCount[#].Count Int32
Count
StopReason UnitName.Admin.StopReason.ID Int32
ID

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In addition to the “Core” tags listed above, the following tags can also provide root cause alarm
information for remote monitoring.
Tag Path Type
Alarm[#] UnitName.Admin.Alarm[#] Alarm
UnitName.Admin.Alarm[#].ID Int32
UnitName.Admin.Alarm[#].Value Int32
UnitName.Admin.Alarm[#].Message String
UnitName.Admin.Alarm[#].TimeEvent TimeStamp
UnitName.Admin.Alarm[#].TimeEvent.Date Date
UnitName.Admin.Alarm[#].TimeEvent.Time Time
UnitName.Admin.Alarm[#].TimeAck TimeStamp
UnitName.Admin.Alarm[#].TimeAck.Date Date
UnitName.Admin.Alarm[#].TimeAck.Time Time

ModeCurrentTime[#] UnitName.Admin.ModeCurrentTime[#] Int32

ModeCumulativeTime[#] UnitName.Admin.ModeCumulativeTime[#] Int32

StateCurrentTime[#,#] UnitName.Admin.StateCurrentTime[#,#] Int32

StateCumulativeTime[#,#] UnitName.Admin.StateCumulativeTime[#,#] Int32

ProdConsumedCount[#] UnitName.Admin.ProdConsumedCount[#] CtnDescrip

UnitName.Admin.ProdConsumedCount[#].ID Int32
UnitName.Admin.ProdConsumedCount[#].Name String
UnitName.Admin.ProdConsumedCount[#].Unit String
UnitName.Admin.ProdConsumedCount[#].Count Int32
UnitName.Admin.ProdConsumedCount[#].AccCount Int32

ProdProcessedCount[#] UnitName.Admin.ProdProcessedCount[#] CtnDescrip

UnitName.Admin.ProdProcessedCount[#].ID Int32
UnitName.Admin.ProdProcessedCount[#].Name String
UnitName.Admin.ProdProcessedCount[#].Unit String
UnitName.Admin.ProdProcessedCount[#].Count Int32
UnitName.Admin.ProdProcessedCount[#].AccCount Int32

ProdDefectiveCount[#] UnitName.Admin.ProdDefectiveCount[#] CtnDescrip

UnitName.Admin.ProdDefectiveCount[#].ID Int32
UnitName.Admin.ProdDefectiveCount[#].Name String
UnitName.Admin.ProdDefectiveCount[#].Unit String
UnitName.Admin.ProdDefectiveCount[#].Count Int32
UnitName.Admin.ProdDefectiveCount[#].AccCount Int32

AlarmHistory[#] UnitName.Admin.AlarmHistory[#] Alarm

UnitName.Admin.AlarmHistory[#].ID Int32
UnitName.Admin.AlarmHistory[#].Value Int32
UnitName.Admin.AlarmHistory[#].Message String
UnitName.Admin.AlarmHistory[#].TimeEvent TimeStamp
UnitName.Admin.AlarmHistory[#].TimeEvent.Date Date
UnitName.Admin.AlarmHistory[#].TimeEvent.Time Time
UnitName.Admin.AlarmHistory[#].TimeAck TimeStamp
UnitName.Admin.AlarmHistory[#].TimeAck.Date Date
UnitName.Admin.AlarmHistory[#].TimeAck.Time Time

PACDateTime UnitName.Admin.PACDateTime TimeStamp

UnitName.Admin.PACDateTime.PACDateTime.Date Date
UnitName.Admin.PACDateTime.PACDateTime.Time Time

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Level 2: “Full.” The full implementation of PackTags adds tags required by the supervisor to support
remote recipe management.

Tag Path Type

UnitMode UnitName.Command.UnitMode Int32

UnitModeChangeRequest UnitName.Command.UnitModeChangeRequest Bool

MachSpeed UnitName.Command.MachSpeed Real

MaterialInterlocks UnitName.Command.MaterialInterlocks Uint32

CntrlCmd UnitName.Command.CntrlCmd Int32

CmdChangeRequest UnitName.Command.CmdChangeRequest Bool

RemoteInterface[#] UnitName.Command.RemoteInterface[#] Interface

UnitName.Command.RemoteInterface[#].Number Int32
UnitName.Command.RemoteInterface[#].ControlCmdNumber Int32
UnitName.Command.RemoteInterface[#].CmdValue Int32
UnitName.Command.RemoteInterface[#].Parameter[#] Descriptor
UnitName.Command.RemoteInterface[#].Parameter[#].ID Int32
UnitName.Command.RemoteInterface[#].Parameter[#].Name String
UnitName.Command.RemoteInterface[#].Parameter[#].Unit String
UnitName.Command.RemoteInterface[#].Parameter[#].Value Real

Parameter[#] UnitName.Command.Parameter[#] Descriptor

UnitName.Command.Parameter[#].ID Int32
UnitName.Command.Parameter[#].Name String
UnitName.Command.Parameter[#].Unit String
UnitName.Command.Parameter[#].Value Real

Product[#] UnitName.Command.Product[#] Product

UnitName.Command.Product[#].ProductID Int32
UnitName.Command.Product[#].ProcessVariables[#] Descriptor
UnitName.Command.Product[#].ProcessVariables[#].ID Int32
UnitName.Command.Product[#].ProcessVariables[#].Name String
UnitName.Command.Product[#].ProcessVariables[#].Unit String
UnitName.Command.Product[#].ProcessVariables[#].Value Real
UnitName.Command.Product[#].Ingredients[#] Ingredient
UnitName.Command.Product[#].Ingredients[#].IndredientID Int32
UnitName.Command.Product[#].Ingredients[#].Parameter[#] Descriptor
UnitName.Command.Product[#].Ingredients[#].Parameter[#].ID Int32
UnitName.Command.Product[#].Ingredients[#].Parameter[#].Nam String
e
UnitName.Command.Product[#].Ingredients[#].Parameter[#].Unit String
UnitName.Command.Product[#].Ingredients[#].Parameter[#].Value Real

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Tag Path Type

UnitModeCurrent UnitName.Status.UnitModeCurrent Int32

UnitModeRequested UnitName.Status.UnitModeRequested Bool

UnitModeChangeInProcess UnitName.Status.UnitModeChangeInProcess Bool

StateCurrent UnitName.Status.StateCurrent Int32

StateRequested UnitName.Status.StateRequested Int32

StateChangeInProcess UnitName.Status.StateChangeInProcess Bool

MachSpeed UnitName.Status.MachSpeed Real

CurMachSpeed UnitName.Status.CurMachSpeed Real

MaterialInterlock UnitName.Status.MaterialInterlock Uint32

RemoteInterface[#] UnitName.Status.RemoteInterface[#] Interface

UnitName.Status.RemoteInterface[#].Number Int32
UnitName.Status.RemoteInterface[#].ControlCmdNumber Int32
UnitName.Status.RemoteInterface[#].CmdValue Int32
UnitName.Status.RemoteInterface[#].Parameter[#] Descriptor
UnitName.Status.RemoteInterface[#].Parameter[#].ID Int32
UnitName.Status.RemoteInterface[#].Parameter[#].Name String
UnitName.Status.RemoteInterface[#].Parameter[#].Unit String
UnitName.Status.RemoteInterface[#].Parameter[#].Value Real

Parameter[#] UnitName.Status.Parameter[#] Descriptor

UnitName.Status.Parameter[#].ID Int32
UnitName.Status.Parameter[#].Name String
UnitName.Status.Parameter[#].Unit String
UnitName.Status.Parameter[#].Value Real

Product[#] UnitName.Status.Product[#] Product

UnitName.Status.Product[#].ProductID Int32
UnitName.Status.Product[#].ProcessVariables[#] Descriptor
UnitName.Status.Product[#].ProcessVariables[#].ID Int32
UnitName.Status.Product[#].ProcessVariables[#].Name String
UnitName.Status.Product[#].ProcessVariables[#].Unit String
UnitName.Status.Product[#].ProcessVariables[#].Value Real
UnitName.Status.Product[#].Ingredients[#] Ingredient
UnitName.Status.Product[#].Ingredients[#].IndredientID Int32
UnitName.Status.Product[#].Ingredients[#].Parameter[#] Descriptor
UnitName.Status.Product[#].Ingredients[#].Parameter[#].ID Int32
UnitName.Status.Product[#].Ingredients[#].Parameter[#].Name String
UnitName.Status.Product[#].Ingredients[#].Parameter[#].Unit String
UnitName.Status.Product[#].Ingredients[#].Parameter[#].Value Real

Tag Path Type

Parameter[#] UnitName.Admin.Parameter[#] Descriptor
UnitName.Admin.Parameter[#].ID Int32
UnitName.Admin.Parameter[#].Name String
UnitName.Admin.Parameter[#].Unit String
UnitName.Admin.Parameter[#].Value Real

Alarm[#] UnitName.Admin.Alarm[#] Alarm

UnitName.Admin.Alarm[#].ID Int32
UnitName.Admin.Alarm[#].Value Int32

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UnitName.Admin.Alarm[#].Message String
UnitName.Admin.Alarm[#].TimeEvent TimeStamp
UnitName.Admin.Alarm[#].TimeEvent.Date Date
UnitName.Admin.Alarm[#].TimeEvent.Time Time
UnitName.Admin.Alarm[#].TimeAck TimeStamp
UnitName.Admin.Alarm[#].TimeAck.Date Date
UnitName.Admin.Alarm[#].TimeAck.Time Time

AlarmExtent UnitName.Admin.AlarmExtent Int32

ModeCurrentTime[#] UnitName.Admin.ModeCurrentTime[#] Int32

ModeCumulativeTime[#] UnitName.Admin.ModeCumulativeTime[#] Int32

StateCurrentTime[#,#] UnitName.Admin.StateCurrentTime[#,#] Int32

StateCumulativeTime[#,#] UnitName.Admin.StateCumulativeTime[#,#] Int32

ProdConsumedCount[#] UnitName.Admin.ProdConsumedCount[#] CtnDescrip

UnitName.Admin.ProdConsumedCount[#].ID Int32
UnitName.Admin.ProdConsumedCount[#].Name String
UnitName.Admin.ProdConsumedCount[#].Unit String
UnitName.Admin.ProdConsumedCount[#].Count Int32
UnitName.Admin.ProdConsumedCount[#].AccCount Int32

ProdProcessedCount[#] UnitName.Admin.ProdProcessedCount[#] CtnDescrip

UnitName.Admin.ProdProcessedCount[#].ID Int32
UnitName.Admin.ProdProcessedCount[#].Name String
UnitName.Admin.ProdProcessedCount[#].Unit String
UnitName.Admin.ProdProcessedCount[#].Count Int32
UnitName.Admin.ProdProcessedCount[#].AccCount Int32

ProdDefectiveCount[#] UnitName.Admin.ProdDefectiveCount[#] CtnDescrip

UnitName.Admin.ProdDefectiveCount[#].ID Int32
UnitName.Admin.ProdDefectiveCount[#].Name String
UnitName.Admin.ProdDefectiveCount[#].Unit String
UnitName.Admin.ProdDefectiveCount[#].Count Int32
UnitName.Admin.ProdDefectiveCount[#].AccCount Int32

AccTimeSinceReset UnitName.Admin.AccTimeSinceReset Int32

MachDesignSpeed UnitName.Admin.MachDesignSpeed Real

AlarmHistory[#] UnitName.Admin.AlarmHistory[#] Alarm

UnitName.Admin.AlarmHistory[#].ID Int32
UnitName.Admin.AlarmHistory[#].Value Int32
UnitName.Admin.AlarmHistory[#].Message String
UnitName.Admin.AlarmHistory[#].TimeEvent TimeStamp
UnitName.Admin.AlarmHistory[#].TimeEvent.Date Date
UnitName.Admin.AlarmHistory[#].TimeEvent.Time Time
UnitName.Admin.AlarmHistory[#].TimeAck TimeStamp
UnitName.Admin.AlarmHistory[#].TimeAck.Date Date
UnitName.Admin.AlarmHistory[#].TimeAck.Time Time

AlarmHistoryExtent UnitName.Admin.AlarmHistoryExtent Int32

PACDateTime UnitName.Admin.PACDateTime TimeStamp

UnitName.Admin.PACDateTime.PACDateTime.Date Date
UnitName.Admin.PACDateTime.PACDateTime.Time Time

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2 PackML States and Modes

The machine specification for a PackML compliant machine must define the supported machine
modes and, within each of these modes, which PackML states are supported. It is suggested that a
table such as the one below be created by the machine builder for each PackML mode:

Mode ID Overview of machine mode action

(“UnitMode”)
Provide label Define ID #

State1 ID Overview of machine state action

(“StateCurrent”)
Clearing 1
Stopped 2
Starting 3
Idle 4
Suspended 5
Execute 6
Stopping 7
Aborting 8
Aborted 9
Holding 10
Held 11
Unholding 12
Suspending 13
Unsuspending 14
Resetting 15
Completing 16
Complete 17

Note that peer-to-peer communication typically requires that this information be made public. In
addition, users may find it convenient to add columns to the table for each of the machine’s
submodules (e.g. infeed, filling section, sorting, out feed, etc.) so that the state actions may be
described on a modular basis.

1
Delete or strike through any unsupported states. Note the state identification numbers given are
fixed by ISA TR88.00.02 and are given here only for clarity.

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