PACKAGING
At the heart of this vision is serialisation, the At the network level, open, real-time bus
systems, such as EtherCAT, allow equipment from multiple vendors to communicate seamlessly, with consistent diagnostics and precise synchronisation. Features like HotConnect and network bridging enable modular machines to accurately synchronise and exchange real-time data without relying on additional non-deterministic network layers, such as OPC UA. The detailed diagnostics of EtherCAT can also rapidly identify cable breaks or EMC interference on a machine or line, helping reduce costly downtime.
THE ‘HOLY GRAIL’ OF PACKAGING For many manufacturers of consumer goods, the ‘holy grail’ of packaging is achieving lot size one. This means being able to produce and package a single customised item with the same efficiency as a mass-produced batch. Coca-Cola’s ‘Share a Coke’ campaign, where
bottles had people’s names printed on the labels, showed the power of packaging when marketed to the individual. Whilst this isn’t true lot size one, as many multiples of each name were produced, this successfully demonstrated how personalisation can elevate the customer experience. Brand awareness and loyalty is harder than
ever to build with increasing market saturation, so new levels of personalisation and premiumisation possible with lot size one are seen as a key market differentiator. It also allows manufacturers to capitalise on evolving e-commerce channels where direct to consumer sales enable fully customised products tailored to the consumers preference and increase further promotion via customer’s social media.
ability to assign a unique identifier or code to every single unit. This concept is already widely used in the pharmaceutical and food industry for compliance and traceability, and is becoming more commonplace among consumer goods, too. Ultimately, serialisation is what makes personalisation, seasonal editions and SKU-level traceability truly possible. To make lot size one and serialisation visible
at scale, packaging lines must have more than mechanical flexibility. What really matters is granular, high-frequency data from every machine, seamless synchronisation between modules and simple recipe-based changeovers. Operators must be able to set up a new format at the touch of a screen, without needing a specialist engineer for every minor adjustment. Meanwhile, packaging machinery must be able to handle complex demands while being intuitive enough for operators with more limited skills to use.
THE IMPORTANCE OF PC-BASED CONTROL PC-based control offers a flexible, open approach to industrial automation that can bring significant benefits to packaging lines. Unlike fixed-function PLCs. Beckhoff industrial PCs (IPCs) are built with industrial-grade components and a rugged design, optimised for real-time automation tasks and long-term availability. These IPCs support an open OS philosophy, enabling the seamless integration of third-party software and existing IT expertise, whether on Windows or Linux. By shifting functions from hardware to
modular software runtimes, PC-Based control ensures machine controls are future-proofed to align with changing factory communication strategies. Beckhoff IPCs can connect with any factory system; OPC UA for MES, MQTT for cloud platforms, REST APIs for ERP, or direct access to local and remote databases, without hardware limitations. EtherCAT networks complement this approach by delivering real-time
communication and detailed diagnostics. They can automatically detect issues such as cable breaks, node failures or electromagnetic interference, enabling engineers to pinpoint and resolve problems quickly before they cause unplanned, costly downtime. TwinCAT software further strengthens this
PC-based approach. For OEMs, TwinCAT offers a free PackML library that provides all the ISA standard data types and state-transition functions needed to implement standardised machine states. For end-users, TwinCAT also simplifies integration with companion standards such as the Weihenstephan Standards, using the TF6100 Nodeset editor for OPC UA to match standard XMLs to PLC variables, streamlining setup without requiring deep knowledge of the software. As well as troubleshooting, PC-based control
supports modular, adaptable line design. Packaging modules, such as labellers and fillers, can be connected and reconfigured with minimal disruption, while real-time diagnostics provide visibility across the system. With this flexibility, lines can respond quickly to changing production requirements, upgrades and expansions become easier and consistent performance is assured. Flexibility, personalisation and efficiency are
the future of the packaging industry. Meeting these demands means more than having fast machines; they need unified, PC-based control, seamless communication between modules and standardised frameworks. By combining real-time data, modular design and open automation technologies, packaging lines can handle complex SKUs, rapid changeovers and fully personalised production. For more information on how PC-based
technology can transform the packaging industry, visit the Beckhoff website and download its brochure:
https://www.beckhoff.com
Beckhoff Automation
www.beckhoff.com
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