Featured Application
Vertical Form Fill Seal Machine Solutions

Vertical form fill seal (VFFS) machines are used in food and other packaging applications that begin with a web of plastic or metal film and end with a finished bag or packaged product. To ensure a reliable, smooth process from start to completion, sensors and indicators provide feedback vital to line efficiency.

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Packaging

A variety of sensors enhance product quality on high-speed packaging lines.

Vertical Form Fill Seal Machine Solutions

Vertical form fill seal (VFFS) machines are used in food and other packaging applications that begin with a web of plastic or metal film and end with a finished bag or packaged product. To ensure a reliable, smooth process from start to completion, sensors and indicators provide feedback vital to line efficiency.

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Multicolored Reflective Package Detection

The manufacturing and verification process of packaged goods is increasingly becoming more complex. Reflective packaging on individual tea bags can be difficult to detect with many sensors. To ensure individual tea bag packets are going into the correct tea box, it is vital to verify packaging and count tea bags as they go down a conveyor.

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Cap Orientation Verification

As plastic or aluminum caps exit a vibratory feeder bowl onto a conveyor, they must be inspected for proper orientation before moving on to the filling and closure process. While most feeder bowls can mechanically control part orientation, it is critical to ensure caps are oriented properly to prevent any issues that might lead to loss of material. A reliable sensor that can withstand aggressive washdown and chemical procedures is needed in pharmaceutical and similar environments.

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High-Speed Registration Mark Detection

Primary packaging has many high-speed processes, and it is important to verify correct packaging, which can be done by detecting registration marks. White registration marks on dark backgrounds, such as blue, can be challenging to detect at high speeds since many sensors are not able to maximize contrast for reliable detection of the mark and not the background.

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Safeguarding a Robotic Palletizer

There are several safety functions involved with a robotic palletizer. The status of the safety devices needs to be communicated to operators. Status monitoring allows operators to ensure everything is running smoothly and ensure no safety hazards exist. A safeguarding solution is needed to control safety light curtains with muting, gate switches and E-stop buttons. The solution also needs to safeguard two conveyors going out, two case infeeds and a forklift entry where empty pallets arrive.

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Detecting Different Size Packages on a Conveyor

When multiple products are sent down the same manufacturing line, variances in size can make them difficult to detect as they move along the conveyor. The best solution is to line up multiple sensors underneath the conveyor to ensure any and all packages are detected.

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Clear Bottle Detection

High-speed applications, such as clear bottle detection, requires reliable position detection. Typically clear bottles are challenging to detect because many sensors will see through the clear object, rather than detect it.

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Clear Container Detection

Plastic container detection is challenging because containers are clear and can have ridges, which may attenuate light differently and can be difficult to detect accurately. In order to count these containers as they move down the conveyor, it is important to have a dynamic sensor that can sense clear or transparent items and do so quickly and accurately.

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Correct Label Verification

Bottle filling lines run many different products and require frequent changeovers. It is important that each bottle is correctly labeled and that the label is consistently affixed to the bottle. To prevent mislabeled bottles and ensure quality, iVU TG Image sensors are able to determine whether a label pattern matches its reference pattern.

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Date/Lot Code Verification

Many food and beverage packaging applications require date/lot code verification to ensure that the date/lot code is printed correctly and legibly. After the date/lot code is printed on frozen dinner carton magazines, they move down the conveyor as the date/lot code is inspected. The food and beverage industry requires a reliable, cost-effective sensing to ensure these codes are correct and legible to help prevent packaging errors.

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Detecting Bottle Caps of Various Colors

Determining whether or not a bottle has a cap requires additional sensing controls when the production line runs products with various colored caps than when sensing like-colored caps. The sensing solution must be able to detect many colors at a specified distance, while ignoring the product inside the bottle.

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Leading Edge Detection of Packages with a Thin, Flexible Edge

Frozen dinners go through many processes during secondary packaging before being stretch wrapped in large boxes for shipment. As frozen dinners come down the line, it’s important each dinner be individually placed into a bucket, so it can enter the carton magazine correctly. Detecting the leading edge of the plastic container—which is usually thin and can vary slightly in position—is essential to isolating dinners into buckets. This process requires a solution that can swiftly detect small objects that may or may not be in the exact position as the previous object.

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Detecting Registration Marks on Labels

During product packaging, labels are printed on a continuous web. The web must be precisely cut to ensure correct placement on containers. This is a high-speed process with frequent changeovers, and misplaced labels will result in costly delays and waste.

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Carton Trigger For Date/Lot Code Printing

When packaging frozen dinners, the date/lot code must be printed on the package and then verified for quality assurance. Because of the cartons’ glossy, multi-color surface, finding a sensor that consistently detects the carton’s leading edge—signaling the precise time to print the date/lot code and capture the image for quality assurance—without excess chatter is challenging.

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Illuminating Inside A Cartoner

Illuminating the inside of a cartoner is vital to ensure the manufacturing process is running smoothly and efficiently. In this example, highly visible lights help light up the area where frozen food trays are being inserted into each carton.

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Packaging Frozen Dinners on a Cartoner

A cartoning machine, also frequently referred to as a cartoner, is a packaging machine that forms various types of cartons, including closed, folded, side seamed and sealed cartons. In addition to forming the carton, many cartoning machines incorporate product loading options. Banner products provide simple solutions for cartoners from beginning to end. In this example, the horizontal cartoner machine forms the carton, fills empty cartons with frozen dinners and then closes the carton on either end. This part of the packaging process requires reliable sensing and safety solutions to ensure a smooth-running process.

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Flap Detection on Cartons in Food and Beverage Industry

In the food and beverage industry, frozen meals go through a step by step checking process on the manufacturing line to ensure they are correctly packaged before shipment. The cartons have a glossy surface, and it can be challenging to find a sensor that will easily detect glossy surfaces and alert operators if the carton flap is open, even if it is just open slightly.

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Carton Profiling

Carton profiling is an important aspect of the packaging industry. It helps ensure cartons and packages make it to the correct area of the factory for shipment. Cartons need to be measured for height, length and width, and the size needs to be communicated to a PLC for proper placement.

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Case Stacker Inventory and Presence Detection

Flat cases are lined up on case accumulator ready to be picked up to go through the formation process. A solution is needed to validate the thickness of flat cases and ensure there are enough lined up to keep the manufacturing process going as quickly and smoothly as possible. The solution also needs to help ensure that only one case is picked up at a time to avoid errors.

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Q4X Versatile, Rugged Laser Distance Sensor

The versatile, rugged laser distance sensor has superior performance, detecting distance changes as small as 1 mm with a reliable sensing range of 25 to 300 mm.

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Q3X Versatile, Rugged Laser Contrast Sensor

The versatile, rugged laser contrast sensor provides reliable, high-speed detection and fixed background suppression models allow for contrast detection in a fixed range while ignoring a background.

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iVu Integrated Vision Sensors

iVu Integrated Sensors offer easy configuration and convenient monitoring right on the sensor.

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iVu Remote Vision Sensors

The iVu Remote Display provides a solution for applications where the sensor location makes it difficult to use an integrated display.

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WORLD-BEAM Q12 Series

PW12-rated rugged ultra-miniature sensor with multiple modes for accurate sensing in confined spaces

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WORLD-BEAM Q20 Series

PW12-rated compact sensor in worldwide standard rectangular housing

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WORLD-BEAM QS18 Series

Universal housing design with 18 mm threaded lens; an ideal replacement for hundreds of other sensor styles

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Sensors Brackets

A wide selection of rugged and versatile mounting brackets including stainless steel, reinforced thermoplastic polyester and swivel models

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TL50 General Purpose Tower Light

Self-contained tower light indicators use long-lasting LED technology, are simple to install, and provide highly visible operator guidance and equipment indication.

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CL50 General Purpose Column Light

Large self-contained indicators use long-lasting LEDs to provide highly visible multi-color indication in a single segment.

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SC22-3E Safety Controller with Ethernet

Non-safety monitoring of the Safety Controller I/O via Ethernet network communications, including Modbus/TCP, Ethernet I/P and PCCC.

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EZ-SCREEN Low-Profile Safety Light Curtain Systems

The space-saving, compact profile of the EZ-SCREEN LP is ideal for smaller machines, yet robust enough to meet the demands of large power presses.

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SLM Series Slot Sensors

Rugged metal sensor detects objects that pass between the opposed-mode emitter and receiver.

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R58 Registration Mark Sensors

3-color registration mark sensor for detecting even subtle differences

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SI-HG63 Hinge Style Switches

SI-HG63 Series Safety Interlock Switches Attached to a Load-Bearing Hinge

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T18 Series

T-style IP69K housing and 18 mm threaded lens with EZ-BEAM style optics and electronics, for reliable sensing without adjustments (most models)

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Document Name File Size Download
1. Colored Marker Cans for Product Changeover Consistently Detected on High-Speed Line 248K Download
2. iVu TG Combines Inspections to Help Detergent Bottler Meet Quality Standards 408K Download
3. Detecting Barcode Presence and Rotation Using Customized Banner Vision Sensor 539K Download
4. Simplifying Safety Feature Management 714K Download
5. Cost-Effective Pallet Detection Solution for Conveyance Equipment 523K Download
6. T-GAGE improves quality control for plastic bottle manufacturer 340K Download
7. T-GAGE improves spout sealing for plastic bottle manufacturer 389K Download
8. Hamer, LLC uses the R58 Expert to solve multi-color registration mark application 467K Download
9. iVu solves label detection application for plastic bottle manufacturer 472K Download

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