Automation solutions in secondary packaging

Cartoning for secondary packaging

Before the cartoning of the primary packaging, a main application in secondary packaging, the conveyor logistics required to transport goods in and out must also be safeguarded. Dynamic, efficient and flexible solutions for safe automation are required, in order to be competitive.

At the exact moment when covers and flaps on plants must be opened, there are other flaps that should be protected, for example to avoid contact with high temperatures such as those that occur while stretch shrink wrapping. Product connectivity and a flexible series connection of safety sensors and control technology not only enable maximum safety for operators, but also ensure the efficiency of the packaging machine.

We offer safe automation solutions for secondary packaging, whether that involves safety sensors, safe small controllers or operating mode selector switches. You can rely on our high level of customer orientation and specialist knowledge of the standards. We're happy to support you with your requirements.

Increase safety on carton erectors

With optical recognition on the carton magazine or cardboard feed on carton erectors, the TÜV SÜD certified solution for PL d / SIL 2 prevents an operator from reaching into the machine through the empty material infeed opening and injuring themself. While there is sufficient packaging in the magazine, the opening is covered and it is impossible to reach into the danger zone while the packaging plant is running. In this scenario, the packaging acts as natural protection and secures the movable guard. If the number of cartons in the magazine reaches or falls below the defined minimum, this will be detected by two optical sensors, which shut down the outputs via the safe small controller PNOZmulti 2 or the modular safety relays myPNOZ. The machine is in stop mode until packaging is again in place.

The combination of optical sensors and safety controller gives companies in the packaging industry an automated solution when it comes to safely monitoring the cardboard feed. If the safety circuit is to be created using configuration software, you automate using PNOZmulti 2. The modular safety relays myPNOZ are configured via the hardware sequence. We'll be happy to advise you on the right solution for you.

How you benefit:

  • Higher productivity when packaging, plus cost saving: packaging provides natural protection; there is no need for fences and the like
  • Higher level of personnel safety: minimised risk of accident thanks to the use of safe control technology in combination with optical sensors, approved by TÜV SÜD
  • Easy to integrate into existing applications, retrofit possible
  • Minimum space requirement due to compact sensor housing and individual installation options to the side of or above the carton magazine
  • Format changes can be implemented efficiently
  • Covers applications for packaging machines in accordance with EN 415

Application examples:

Example application: solution prevents accident risk
  • The TÜV SÜD certified solution for PL d / SIL 2: greater safety for personnel, minimised accident risk.
Example application: no hazard on the machine
  • Sufficient cartons in the magazine: no danger!
Example application: machine in stop mode
  • The machine is in stop mode until sufficient cartons are again in place.

Solution with the safe small controller PNOZmulti 2 and optical sensors

  • Flexibility: all base units PNOZmulti 2 can be used and are certified
  • One-stop shop: all other application-based safety functions can also be monitored (E-STOP, safety gates etc.)
  • Production: integrated diagnostics via PVIS, with plain text messages for quick resolution of downtimes with clear instructions
  • Cost-optimised: possible to monitor two carton magazines with just one base unit: one function block is configured and 2 sensors are needed per magazine

More about optical sensors

Safe monitoring on carton magazine TÜV SÜD certified for PL d/SIL 2

Solution with modular safety relay myPNOZ and optical sensors

Safety on carton erector TÜV SÜD certified for PL d/SIL 2
  • Pre-configured: Creator type code PNOZ.91.CKA360AB000XB700 (with semiconductor outputs)
  • Pre-configured: Creator type code myPNOZ.03.CKA360AB000XD700 (with relay outputs)
  • Plug & play: in conjunction with the sensors, easy to wire - ready to use instantly
  • Simple: diagnostics via LEDs
  • Flexible: possible to monitor additional safety functions Creator type code must remain as certified, but can be customised (see documentation for details)

More about optical sensors

Rapid fault detection and high plant availability

Intelligent, networked production processes can significantly increase the productivity of your packaging machine. However, this is only possible if a wide variety of data is automatically available. With our diagnostic solution Safety Device Diagnostics, you can record diagnostic data such as individual serial numbers, version status, current states and error states. Fastest possible fault detection ensures short downtimes.

You can then use your diagnostic data for predictive maintenance when stretch shrink wrapping, for example.

Application: film shrink wrapper

Safety for the robot cell

Safeguarding a robot cell

The I/O module PDP67 PN with Profinet/Profisafe interface ensures safety where there is no room for a control cabinet, in a robot cell for example. Thanks to the IP67 protection type and robust zinc housing, it is ideal for use outside of the control cabinet. Even at temperatures of -30°C to 70°C, it reliably passes the sensor and actuator data on to the higher level controller!

As a result, the robot is guaranteed to go to a safe state as soon as your employee gains access to the machine.

More information about packaging technology


Pilz Ireland
Business and Technology Park, Model Farm Road

Telephone: +353 21 4346535

Technical Support

Telephone: +353 21 4804983