Packaging

As a continuous process, the filling and capping machine sets the pace for the entire packaging line and must be constantly supplied with containers.

• Random container position detection: The XX ultrasonic sensor is an ideal solution for detecting containers in the buffer area, regardless of the material's reflectivity. Its right-angle format eases installation, eliminating the need for additional mechanical components. 
• Reliable Container Counting: The versatile XU photoelectric sensor, equipped with multiple photocell technologies, ensures accurate counting by detecting a wide range of packaging materials.

Environment

• Machine access is secured to prevent contamination. The XCSRC contactless RFID safety switches, certified to IEC 62061 SILCL3, monitor door status to ensure compliance with the ISO 13849-1 PL e machine safety standard.
• As filling and capping machines are cleaned with detergents, stainless steel sensors with IP69K or Ecolab certification are required for durability.

Filling area

• Precise Nozzle Positioning: The XS inductive sensor ensures accurate and repeatable detection of filling nozzles.
• Filling Completion Monitoring: The XT capacitive sensor, available with a plastic or metal frame, provides reliable monitoring based on the machine’s cleaning requirements.

Capping process

• Cap Detection: The XU photoelectric sensor monitors cap position and color to ensure proper application.

Outfeed:

• Quality Control & Rejection: At the station’s end, incorrectly filled or uncapped containers are rejected. The perfect solution integrates the XUYF fork sensor, designed for easy installation, with the cylindrical XUB photoelectric sensor, which features a right-angle connector that minimizes cable footprint.

Similar to the filling process, labelling machines are often positioned in closed and restricted areas with doors often monitored by contactless RFID safety switches, certified IEC 62061 SILCL3.

The labelling machine requires an accurate and high responsive label detection to ensure precise positioning of the label on a container. Both ultrasonic or photoelectric sensors with a fork design are suitable for the label application, ensuring high efficiency and limiting the waste of labels.

Bottles and Carton Handling:

• A highly precise solution is required to detect each thin carton fold in a stack. XUM laser sensing technology ensures accurate detection for this task.
• To ensure suction cups grip each carton fold with sufficient pressure, the XMLP electronic pressure transmitter precisely monitors pressure.
• To prevent overtravel at the end of the linear axis, the XCMH limit switch provides a compact and reliable solution.

Conveyor:

• To detect outfeed cartons and activate conveyor drives while preventing jams, the XX ultrasonic sensor with a wide beam reliably detects the random positioning of carton boxes.
• Frequent operator movement around the conveyor can damage sensors installed at regular intervals. To prevent misalignment or damage, the XUY roller photoelectric sensor is fully integrated between conveyor rollers, eliminating exposure to impact.

Palletizing robot:

• This area must remain safe for operators while monitoring infeed and outfeed conveyors. The XUSL4M light curtains, certified to IEC 62061 SILCL3, ensure compliance with ISO 13849-1 PL e machine safety standards.
• The pallet stacker must continuously deliver individual pallets while anticipating an empty stack to avoid process interruptions. The XX ultrasonic sensor, with an 8m right-angle detection range, effectively monitors this process.

Wrapping Posts

• Precise Film Application: The XUK8T Time-of-Flight photoelectric sensor monitors both the position of the film applicator and the distance between the applicator and the rotating pallet, ensuring uniform film wrapping.
• Overtravel Monitoring: The XCKP limit switch, designed for robustness and vibration resistance, effectively monitors top and bottom overtravel.
• Continuous Film Supply: The XX ultrasonic sensor with an analog output anticipates when the wrapping film roll is nearing depletion, ensuring uninterrupted operation.

End of Packaging Line

• Pallet Detection: The XU photoelectric sensor with Blue Light technology in diffuse mode with Background Suppression reliably detects pallets approaching the loading area, regardless of package material (shiny, dark, etc.).
• Forklift Approach Monitoring: The XX wide-beam ultrasonic sensor detects approaching forklifts and activates a Warning Light for enhanced safety.

Environmental Considerations

Palletizing and wrapping machines are often located in dusty and humid environments, typically near the loading area. To ensure durability and reliability, sensors with a minimum rating of IP67 (IEC 60529) should be used.