Applications
for Efficiency

REVOLUTIONIZING OEEIN PACKAGING
FOOD AND BEVERAGE​

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Food and Beverage Automation

ARE DOWNTIME AND
PRODUCT QUALITYIMPACTING YOURPRODUCTION EFFICIENCY?
While unplanned downtime can have many causes, such as material
shortage, component failure, process jamming, or operator error,
many of these problems can be minimized with the right plan.
With proper management, even planned downtime, for required tasks
such as product changeover, cleaning or scheduled maintenance,
can be limited. By focusing on Overall Equipment Effectiveness (OEE),
you can greatly reduce machine failures, set up times, idling, minor stops,
reduced speeds, product defects, and waste, and gain more uptime.
This guide contains applications, case studies and technology
considerations to help OEMs and manufacturers identify existing issues
and offers Balluff-developed solutions to address them. This is donewith a focus on seven core application areas: controls architecture, formatchange, predictive maintenance, level sensing, robotic automation, andquality assurance. These applications have been tested in real world
production and utilized by engineers, owners and managers at OEMsand manufacturers around the world to revolutionize OEE in the foodand beverage industries.
Dramatically shorten planned downtime and changeover time
Add flexibility to production, allowing for shorter runs and more variety■ Reduce equipment build and installation time
■ Increase efficiency, flexibility and visibility by utilizing IIoT andsmart technologies■ Improve product quality with traceability and error-proofing solutions■ Eliminate unplanned downtime caused by failed automation 		
components and processes■■

www.balluff.com

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CONTENTS
8 Overall Equipment Effectiveness10 Rethinking Plant Controls
12 OEE Application Areas

6

REVOLUTIONIZING OEE
16 Controls Architecture
18 Format Change
20 Predictive Maintenance
22 Level Sensing
24 Robotic Automation
26 Quality Assurance
28 Conveying

14

APPLICATION AREAS
32 Controls Architecture
34 Format Change
36 Smart Sensors
38 Quality Assurance

30
CASE STUDIES
42 What is IO-Link?
44 Industrial RFID
45 Condition Monitoring
46 Guided Changeover Solution
48 Optimal Performance
52 Smart Automation and Monitoring System (SAMS)

40
TECHNICAL CONSIDERATIONSWEBSHOP AND ACCOUNT PORTAL 53
GLOSSARY54
GLOBAL PROJECT MANAGEMENT 56
ABOUT BALLUFF 58

www.balluff.com

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Boost Productivity

REVOLUTIONIZING OEE IN
FOOD AND BEVERAGE
MANUFACTURING

A review of our top partnerships in food and beverage manufacturingshows that availability, performance and quality are improved throughcollaborative efforts. Manufacturers and OEMs who embrace anapplication philosophy have found dramatic reductions in changeover
time, eliminated product defects and shortened unplanned downtime.
This application philosophy positively impacts OEE, brings automation
technology and Industrial Internet of Things (IIoT) technologies into theplant, and generates value for the organization by improving production
efficiency, enhancing product quality and adding flexibility for shorterproduction runs.

www.balluff.com

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YOUR PARTNER IN
OVERALL EQUIPMENTEFFECTIVENESS
When striving to increase production with fewer losses, many food and beverage managers measure the efficiency andeffectiveness of their processes utilizing the Overall Equipment Effectiveness (OEE) philosophy. To help our customers
achieve valuable improvements to their OEE, Balluff has worked with manufacturers and OEMs to incorporate strong
automation technologies that improve availability, expand performance and enhance production quality. We use ourpassion for automation and innovative technology to decrease loss-related factors and help you achieve your goals.

Improve Availability

Enhance Quality

We want to work with you to increase
machine output. This is done with afocus on improvements to planned
downtime factors, like setup time andequipment changeover. In addition,
unplanned downtime and machine
failures can be dramatically reduced with
monitoring and technology fit to thespecific application. We can help you
improve the availability of the equipment
to produce more product.

We want to work with you to reduce
waste of all kinds in the plant. We canwork toward eliminating production
rejects and product defects by errorproofing processes. Shorten the waste
created during startup and the high levelof rejects during this window to improve
the overall yields of the production run.
Know where material is, where it camefrom and where it is going at every stepof the process.

Expand PerformanceYour Partner

Reviewing the causes of small stops
and slow cycles can generate insights
into the process and help to expand
performance. By monitoring the statusof key components of the machine, we
can identify and eliminate causes of
idling, minor stops and reduced machine
speed. We can then work to get themachine as close to the ideal cycle time
as possible. Expanded performancecan be accomplished through anunderstanding of your goals andreviewing the total cost of ownershipof a problem.

Those who choose Balluff have along-term partner working with themto improve production. To revolutionize
OEE, we use proven automation
application areas: controls architecture,format change, predictive maintenance,level sensing, robotic automation, quality
assurance and conveying. By working
together, we can achieve overall
equipment effectiveness and efficiency
in the machine, the production line andthe plant.

UNP
DOWLANNE
NTI D
ME

ED
PLANN IME
T
N
DOW

REDUCEDYIELDSSLOWCYCLESSETUP

MACHINE
FAILURES

SMALL
STOPS

STARTUPREJECTSCHANGEOVERPRODUCT
DEFECTSPROD
UWAST CTE

PRODUCTIONREJECTS

MINOR
STOPS

IDLING

REDUCED
SPEEDSwww.balluff.com

Revolutionizing OEE in packaging, food and beverage | 11

RETHINKING PLANT CONTROL		SYSTEMS FOR GREATER VISIBILITY
Many manufacturers in food and beverage operate with a decades-old supervisory control and data acquisition (SCADA) system.
For field level devices, sensors and I/O, it is not uncommon to see hardwiring and Devicenet/Profibus networks. Older generationsof SCADA systems rely on difficult to support mainframes, old local area networks (LANs) and process control networks (PCNs).
These older SCADA systems can limit overall equipment effectiveness. Newer systems are supportive of smart factory concepts,
can be networked and are web-based, creating more flexibility, more efficiency and more visibility into the production processes.
By utilizing Ethernet for the communication between smart devices, PLCs and our SCADA system, we can more easily create
visibility into the lowest field level of the process. But it isn't always logical to use an Ethernet infrastructure for a simple inductive
proximity switch or photoelectric sensor. The well-established, open-standard IO-Link fills this gap. It simplifies the controls
architecture by providing process, parameter and diagnostic data on a single network. IO-Link reduces the number of nodes on
a network, reducing traffic and demands on the PLC while simultaneously providing visibility down to the field device.

Personal Device

TRADITIONAL CONTROLSARCHITECTURE

SMART CONTROLSARCHITECTURE

Database

SCADA Software

Information (TCP/IP, Ethernet, DH+)SCADA Software

■
■
■
■
■
■
■
■

HMI

Ethernet IP
Profinet
EtherCAT
Information
Control
DevicesDiagnostics
Configuration

Database

Control (Remote I/O, Control Net)
Profibus
IO-Link master
HMI

VFD

I/O

Servo Drive

VFD

Servo Drive

I/O

Device (Devicenet, AS-i)
IO-Link devices

Proximity
SensorPhotoelectric
Sensors

Soft Start

HMI

I/O Blockwww.balluff.com

Revolutionizing OEE in packaging, food and beverage | 13

OEE APPLICATION AREAS
Overall equipment effectiveness, zero downtime and the demand forshorter production runs is driven by applying innovative technology
solutions to create smarter machines. Balluff has responded to the foodand beverage market’s frustrations with these proven application areasthat positively drive uptime and run yield.
Controls Architecture
Format Change■ Predictive Maintenance■ Level Sensing■ Robotic Automation■ Traceability■ Conveying

PALLETIZERS AND 		SHRINK WRAPPERS​​FILLING AND LABELING■■

Robotic automation​
Controls architecture■ Predictive maintenance​■ Quality assurance: traceability■

Level sensing​■ Format change ​■ Controls architecture​■ Predictive maintenance​■ Quality assurance:
error proofing■

TANKS AND STORAGE
Level sensing​Controls architecture​■ Predictive maintenance​■ Quality assurance: traceability■■■

CARTONERS AND CASE ERECTORS​Format change​
Controls architecture​■ Predictive maintenance​■ Quality assurance: error proofing​■ Robotic automation​■■

CONVEYORS AND
MATERIALS HANDLING​
Format change ​Controls architecture■ Predictive maintenance​■ Quality assurance: traceability■ Condition Monitoring Tool Kit(CMTK)■ Conveying■■

CONVEYINGCONTROLS ARCHITECTURE

FORMAT CHANGE

PREDICTIVE MAINTENANCELEVEL SENSINGROBOTIC AUTOMATIONTRACEABILITY

Provides condition
monitoring■ Provides flexibility
in installation■ Enables traceability■ Supports robotic
picking■

Eliminates analog wiring andreduces costs by 15 % to 20 %■ Simplifies trouble shooting■ Enables visibility down to thesensor/device■ Simplifies retrofits■ Reduces terminations■ Eliminates manual configurationof devices and sensors■

Eliminates changeover errors
Reduces changeover time,minimizing planned downtime■ Reduces product wastefrom start up after changeover■ Maintains consistent positioning■ Ensures proper change
parts are swapped out■

Enhances diagnostics
Reduces unplanned downtime■ Provides condition monitoring■ Provides more accurate data
■ Reduces equipment slows
and stops■ Reduces product waste■■

Reduces wiring
Reduces weight■ Integrates with robotics controller■ Simplifies installation■ Connectorless quick disconnect foreasy swap-out of end of arm tooling■ Provides continuous diagnostics■■

Eliminates false triggers
Compact design■ Easy to retrofit■ Multi-functional with condition
monitoring available

■

■

■

■

Delivers accurate data andreduced errors■ Tracks raw materials and finished goods■ Accurately provides date and lot codefor potential product recall■ Allows robust RFID tags to beembedded in totes, pallets,
containers and fixtures■ Increases security with access control

www.balluff.com

Revolutionizing
and beverage
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15
Revolutionizing OEEOEE inin Packaging,packaging, Food
food and

Improving Effectiveness

APPLICATION AREAS
It can be hard to know where to start a process improvement project.
Traditional solutions may be working adequately but driving to the nextlevel of improvement seems out of reach. With a focus on applications
that solve availability, performance and quality issues, productivity gains
can be easily found. Machine builders and manufacturers alike are surprised by the depth of the returns these application areas bring to foodand beverage production processes. In this section we will review themost common applications, how they can be applied to improve OEE
and provide real world case studies of others' successes.
Controls architecture
Format change■ Predictive maintenance■ Level sensing■ Robotic automation■ Quality assurance■ Conveying■■www.balluff.com

Revolutionizing OEE in Packaging, Food and Beverage | 17

CONTROLS ARCHITECTURE
In controls architecture there are many simple improvements machine builders and manufacturers can easily integrate
into their processes. For equipment OEMs, there is value in simplifying the controls quotation process, shrinking controls
cabinets, maximizing spares, and expediting the build process. For manufacturers, improved controls architecture cansimplify the network, allow for faster troubleshooting, reduce unplanned downtime, and can eliminate headaches causedby analog devices. The IO-Link controls architecture provides IIoT-ready applications and easily supports traceability
applications. By implementing IIoT, you enable additional value to the other application areas.

SIMPLIFY DISCRETE WIRING ÁND VALVE MANIFOLDSSAVE ON ANALOG WIRING AND INTEGRATIONGAIN FLEXIBILITY AND EXPANDABILITY

VISIBILITY DOWN TO EACH SENSOR

Simplify the labor involved in parallel wiring a valve
manifold or terminating a set of discrete sensors.
Distributed I/O reduces hardware setup, while labor can
be customized to reduce I/O hardware costs.

When using analog devices on a machine it can bedifficult to find a path for the shielded cable that does
not incur noise from motors or other complications.
By putting the analog I/O right at the signal’s source,
the complications and costs can be reduced by
15 – 20 %. Utilizing IO-Link, the analog to digitalconversion is done inside the device, and a standard
sensor cable delivers noise-free feedback. In addition,
the smart device reports engineering units (mm, PSI,°C)
which reduces the effort to program and integrate.

By using existing equipment infrastructure and networks,
controls architecture utilizing IO-Link reduces costs ofwiring, labor and control panel size. Any combination ofvendors can be utilized between masters and devices.
With discrete I/O hubs, up to 480 I/O points can be usedwith one IP address connection to the PLC. And with anopen IO-Link master port available, future expandability
or error-proofing solutions can be easily integrated into
the machine with unlimited possibilities.

Controls architecture is about connecting devices in asmarter way on the plant floor. These connections deliver
new ways to generate and collect useful data. By
providing visibility into the process, IIoT allows for
significant improvements, including more predictive
maintenance and data analytics. With IO-Link you cancreate visibility down to each sensor and gain theflexibility and reliability needed for sustainable growth in
the global market. Data can be captured, and theresulting analytics can be used to drive decisions.

The typical parallel wiring of valve manifolds can be labor
intensive and takes up significant cabinet space. OEMs
have saved 15 – 60 % per valve in hardware, engineeringand labor costs by switching to IO-Link valve control.

Traditional analog I/O
Analog output – measuring singal and set points
IP20 I/O

PS

CPU

IN

OUT

Cloud
PLC

PS

Shielded
cable

Reduce thecomplexity of thecontrols cabinet

9 conductors

IO-Link analog I/O interface
Analog to digital conversion

IO-Link
masterUNLIMITEDPOSSIBILITIESIO-Link network
interface
Discrete
Sensors
Simplify
your network

Valve
Manifold

Discrete I/O
Non-shieldedcable

3 conductors
RFID
Identification

Dicsrete
Sensors

Smart
Sensors

IO-Link analog smart sensors
Analog to digital conversion
I/O
Hub

Sensor

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■
■
■
■
■
■
■
■
■

Device ID
Change function
Temperature
Healthy sensor
Lens dirty
Switch count
Suboptimal target
Current/voltage
Measurement
Alignment/inclination

Data

IO-Link network
interface
SmartLight
Non-shieldedcable

3 conductors

Valve
Manifoldwww.balluff.com

Revolutionizing OEE in packaging, food and beverage | 19

FORMAT CHANGE
Many factors can impact availability during a production line format changeover, including incorrect settings, mismatched change
parts, obstructed product flow, blocked sensors, machine tweaking, and slow startups. Using automation technology ensuresproper change parts are present and guiderails are set to their proper distance. Operators can be guided to make consistent,
accurate and quick changes to the format of the machine, reducing planned downtime and shrinking startup waste.

GUIDED FORMAT CHANGE – LINEARGUIDED FORMAT CHANGE – ROTARYAUTOMATIC SIZE CHANGE

CHANGE PART IDENTIFICATION AND VALIDATION

When manually changing the format of the machine,
workers often use visual marker ticks or flags to set themachine. But these can create errors and require lengthy
startup times. In applications with operator guidance,
visual feedback and position measurement sensors
reduce downtime time and ensure position accuracy.
Guided format change technologies provide the operator
visual cues to guarantee proper setup, thereby reducing
startup waste and operator training.

Digital position indicators are commonly used to provide
operator feedback in guided format change applications.
Hand cranks and wheels are used to adjust guide rail
positions, modify equipment heights and adjust the
automation for each format the equipment is designed toaccommodate.The smart rotary devices are programmed
to instruct the operator on the proper position andguarantee perfect setup at each changeover event. By
providing visual cues at the change-point and feedingvalues to the control via IO-Link, the guided formatchange can reduce issues at startup.

Machine OEMs want to reduce the changeover time of
their machine. Electric motors and pneumatic actuatorswith closed loop sensor feedback are the main tools forachieving significantly faster changeovers. By using
automatic size change, accurate positions can be quickly
achieved every time. And with IO-Link, integration is
simplified. Add-on packages can be offered, and analog
headaches are removed. A variety of linear and rotary
position sensing technologies are available to best fit toeach changeover application, ultimately preventing
machine crashes and eliminating waste at startup.

Many format change applications require the machine
operator to replace hardware with different components.
A change in recipe or package size can require plates,
rails or guides, pusher arms, flap folders, pickup frames
or tape heads to be changed. These parts can look very
similar from package to package. RFID tags can be used
to identify and validate all correct mechanical change
parts are installed before startup. For OEMs, this canensure only branded change parts are utilized with themachine to maintain the warranty. Industrial RFID
eliminates mistakes and machine crashes, andguarantees fast and easy startup.

Traditional manual
position ruler

1
2
3

BNI SmartLight
BTL Linear position sensor
BNI IO-Link master

4

BDG Digital position indicator

5

BMP Magnetic position sensor

6
7

BIS IO-Link RFID read/write head
BIS RFID data carrier tag

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 21

PREDICTIVE MAINTENANCE
In most facilities, maintenance crews and operators typically only respond to a problem only after it causes a production stop or
quality issue. Hard stops due to component failure can cause long downtimes and major repair efforts. And most problems occurin spite of regular preventative maintenance routines. By using smart sensors, diagnostics, event data and condition monitoring,
you can reliably detect or predict equipment or components failure before a catastrophic downtime occurs. Predictive
maintenance efforts can dramatically improve OEE of equipment by reducing unplanned downtime events.

DEVICE DIAGNOSTICS AND EVENT DATAMACHINE CONDITION MONITORINGDEVICE CONDITION MONITORING

DIGITALIZATION, VISUALIZATION AND IIOT

Many sensors and automation components work well
until they don’t. There is little to no warning that a failureand downtime are going to happen. Intermittent failures
or poor detection quality can cause nuisance stops andslow production runs. Smart sensors and devices with
IO-Link provide improved visibility and make maintenancetasks more accessible, keeping the equipment runningwith the best efficiency. Diagnostics provided by theindividual intelligent devices highlight impending problems
and speed recovery. Operators can provide technicians
exact details of the failure, saving pricey repair time.

OEE is a measurement of the effectiveness and efficiency
of a production machine’s availability, performance andoutput quality. Using condition monitoring data allows us
to correlate production events to changes in OEE. Thisdata, along with long-term trends and statisticalevaluation of the machine's condition, can predict future
failures or detect production issues before they become
major downtime events. Monitoring machine states likevibration, humidity, temperature or ambient pressure
gives key insights into machine health before an event
occurrs. Predictive maintenance activities can then be
performed during changeovers or scheduled shutdowns,
eliminating unplanned downtime and premature stops
during production.

Major pain can come from failure of individualcomponents like bearings, linear drives, spindles, motors,
gearboxes, or auxiliary units like fans and compressors.
Continuous condition monitoring of the status and healthof these components can eliminate many failure states
like worn bearings, belt buckling, frictional rubbing, partchatter, unbalance, loose bolts, or soft foot. This data
can help predict failures and provide true improvements
to OEE by reducing unplanned machine downtime due tomechanical failures and increasing component life.

When doing projects with smart sensors and condition
monitoring, it can be challenging to determine predictive
maintenance calculations and trending. It can also bechallenging to efficiently bring data together from multiple
systems. With a goal to increase your productivity, we
help with providing the right data in order to create
visualizations for your predicitive maintenanceapplications. Finding a partner to help you collect all
production-relevant data, support technicalimplementation tasks and build application-specificsolutions is a viable option for overwhelmed plant floor
engineers and maintenance teams.

Identify and solve
problems faster

Possible diagnostics provided:
Device present
Device powered■ Marginaloperation■ Lens dirty■ Target beyond sensing range■ Short circuit detection■ Overload detected■ Open output coil
■
■

1
2
3

BNI SmartLightBCM Condition monitoring sensor​
BNI IO-Link master

www.balluff.com

Revolutionizing OEE in Packaging, Food and Beverage | 23

LEVEL SENSING
In food and beverage applications many raw materials are stored and moved through the plant. These can include a variety of
textures, powders, liquids, viscosities, and bulk solids. Many plants rely on operators to maintain process tank levels by manuallylooking into manways and ports, instead of using more reliable level sensing technologies. Without sensing on tanks, processes
can run dry without an operator’s knowledge, and waiting for new deliveries can halt production for hours or even days. Whenfilling, tanks can overflow, creating hazards and material waste in the work areas. The ability to reliably measure all materials instorage containers is key to driving higher OEE through maintaining the quality of product produced and expanding performanceof the line.

DISCRETE LOW AND HIGH LEVELS IN TANKS
Running out of material mid-production can cause highvolumes of scrap product and wasted production time.
In a manual process, additives, seasonings, or other key
ingredients could run empty if an operator fails to verify
material quantity. Discrete sensors provide reliable limit
levels for tanks and containers. High and low points canbe tied to a pump controller for automatic refilling when
low and turning off when full. Detection on stainless tanks
can occur without media contact using a sight glass andcapacitive or photoelectric technologies. Leak detectionis also possible using capacitive technology. Levels in aplastic tank are typically measured without media contact
through the wall of the tank or by using switch-wells.

CONTAINER AND TANK CONTINUOUS
LEVEL MONITORING
It is often more advantageous to know exactly how muchmaterial is in a tank or container. This can be achieved
with a variety of measurement and level sensing sensors.
Linear position sensors with a float could even be used
under strict hygiene guidelines. Self-adhesive capacitive
strip sensors measure levels in non-metallic containers
without contacting the media. Each solution provides
awareness of the exact volume of material remaining andcan signal possible material shortage setbacks.

LEVEL VISUALIZATION AND AUTO-REPLENISHMENT
In level sensing applications it is helpful for operators andsupervisors to easily discern tank levels. Level indication
lights provide simple visualization of each tank's status.
Capabilities for monitoring and visualizing tank levels is
easily possible with IO-Link smart devices andcustomized dashboards through integration services. In
addition, solutions are available that allow for tanks to bemonitored in a dashboard using smart sensors, sharedwith the SCADA system, and visualized at the tank using
a light. They can even provide automated material
replenishment to ensure production never runs dry.

5

8

8

8

2
3

2

1

4

6

9

10

7
4

1
2
3
4

BCS Capacitive leak detection sensor​
BCS Capacitive level sensors without media contact
BGL Photoelectric fork sensor​s
BCS Hybrid smart level sensor​

56
7

BTL Magnetostrictive sensors
for fill level measurement
BCW Capacitive sensors with special properties
BAE Amplifiers for capacitive sensor heads

8
9
10

BNI SmartLight
BNI IO-Link master
BAI Software and solutions

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 25

ROBOTIC AUTOMATION
Demands for automation and workforce shortages are driving record use of robots in food and beverage manufacturing. And as
we work to improve OEE in the plant, there are many tools that can be used. With robots, reducing idle time and increasing work
time is a key to gaining a return on investment. By using inductive coupling and light-weight remote input/output devices, fully
automatic tooling changes can be executed even with pneumatic solenoids on the end-effector. Traditional grippers are improvedby utilizing smart sensors which provide diagnostics and allow for automatic parameter modifications in format changeovers.
Sensors, networking, vision, and IO-Link devices dramatically improve the effectiveness of robotic equipment, boost robot
utilization and increase flexibility of applications.

CONNECT SMART I/O DIRECTLY TO THE ROBOTFAST AND AUTOMATED TOOLING CHANGESCREATING SMART GRIPPERS WITH SMART SENSORSAUTOMATET PICKING AND DEPALLETIZINGThe more we automate, the more complex the controls
architecture and wiring can feel. Internal dress packs
have limited conductors available for sensor and actuatorsignals. Robotic integrators have realized that IO-Link
smart devices are vendor agnostic and can be useddirectly with most modern robot controllers without
interfacing first with an automation PLC. This directconnection can quicken process times and simplify thecontrols architecture. In addition, with only 3 to 5 wires,
an IO-Link signal can be used to control dozens of
sensors and pneumatic solenoids on the end-effector,
including diagnostics and automatic format change
parameterization capabilities. By utilizing IO-Link I/O hubs
to simplify inputs and outputs, robotic automation
applications are more flexible and effective.

Robots capable of multiple tasks or recipes candramatically expand the performance of the production.
With inductive coupling, power and signals are sent
wirelessly without contact across a small airgap from thearm to the tooling; and it boots quickly! Solenoid valves
are controlled on the end-effector reducing the number ofairlines to couple. Sensor signals are collected with an
IO-Link sensor input hub allowing for only a few
conductors to carry the tool ID and many sensor signals
to the control. Inductive coupling I/O technology allows
for fast tooling changes of the end-effector of the robot,
reducing idling and shortening planned downtimes.

Sensors are not often used in traditional pneumatic
gripper applications. Proper function is assumed. Thiscan cause unnecessary collisions or process failures due
to stuck/worn mechanical components, leaks in thepneumatic lines, or small variations in the process cycle.
Adding sensors to the gripper creates a closed loop anddiscrete open/closed feedback. This is done by detecting
the jaw with an inductive sensor or detecting the piston
magnet with a magnetic field cylinder sensor. By using
position sensors, the exact gripper jaw position is known
and used to measure or identify the object in the jaws.
With smart sensors, application diagnostics can bereported to dramatically improve the capabilities of therobot end-effector.

Picking and order picking using robots can greatly
increase the efficiency of these labor-intensive processes.
The prerequisite for this is reliable identification of thematerials to be picked by the robot. With an integrated
processor and application-specific software modules
on the camera, this product family offers autonomous
3D image processing. Information such as pick
points is passed directly to the robot application,
ensuring efficiency.

1
2
3

BNI IO-Link discrete I/O hub​BAE Heartbeat® power supply​
BNI IO-Link master​

4
5
6

BNI IO-Link valve interface
BIC Inductive coupler remote​
BIC Inductive coupler base​

7
8
9

BES Inductive sensors
BMF Magnetic field sensors
BMP Magnetic field position sensor

10 BVS 3D camera

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 27

TRACEABILITY AND INSPECTION
It is important to identify and prevent defects before they reach the consumer. This can be challenging depending on thecompany's quality assurance principles, and how the company limits human error. Quality assurance departments work to meetstandards and legal requirements, provide record keeping, create reporting, and solve problems. For true OEE value to berealized, it is also essential to inspect and monitor product as it is being produced, record the cause for deviations, and track
uptime, output and waste. By implementing error proofing and traceability applications, you can reduce recalls, minimize losses,
enhance food safety and produce product with less stress.

ERROR PROOFING IN FILLING AND BOTTLING ​In filling and bottling processes the sealing/capping
process is a critical step. Missing caps, cross threading,and over tightening cause downtime and create waste.
Ensuring the exact fill level is another vital process, andeven a legal requirement in some plants. Many
manufacturers realize quick improvements in OEE byimplementing error proofing automation with sensors to
identify any defects and enhance quality assurance
initiatives.

TRACE PRODUCTS WITH BARCODES, 2D CODESAND DMC CODES
The new BVS IdentSensor expands the existing rangeof stationary code readers from Balluff. Developed forthe precise reading of barcodes, 2D codes and DMC
codes, it provides simple and flexible communicationinterfaces to the process and IT network. Modern,future-oriented programming interfaces (REST API,
MQTT) and dedicated industrial interfaces (IO-Link, TCP,
UDP) as well as additional condition monitoring
information make the sensor unique and ideal for use in
fast and difficult processes in automated production.

TRACK AND TRACE IN PRODUCTION​

TRACEABILITY OF REUSABLE CONTAINERS ​Some products require detailed information of the
production processes to ensure traceability of the workand raw materials used. When this is needed, industrial
RFID systems are utilized for work in process (WIP)
tracking of the production activities. The product carrieror transport is affixed with an RFID data tag that contains
detailed information about the production such as who
did the work, when the work was completed, or whatbatch of material was used to make the product. Everyaction has data making it possible to find and containdefects quickly.

As raw materials and ingredients in a plant are commonly
loaded into reusable containers, the ability to store
information with this material is critical for safety andreduces the level of waste in the plant. Industrial RFID
systems allow the reusable containers to be tagged andtracked. Time stamps, type of material and productmovements are reported to the MES system; while criticalprocesses, like cleaning cycles and spoilage times, arealso monitored. RFID gateways or handheld barcode
scanners can be used to track where a bin was stored,making it easier to find and ensuring that the propermaterial is used at the proper production location.
Traceability in the factory for reusable containers
minimizes economic losses and improves food safety.

BVS IdentSensor

Missing cap

Low fill

Good

Good

Cross threaded

Over filled

1
2
3

BIS IO-Link RFID read/write head
BNI IO-Link master ​BIS RFID data carrier tag

4
5

BIS UHF read/write system
BIS Portable barcode reader

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 29

CONVEYING
Transporting, sorting, loading and unloading, buffering, accumulating – in all intralogistics tasks, throughput and availability
at the right place at the right time are what counts in the end. Goods must get from A to B as efficiently as possible.
And it must be done with maximum flexibility, since batch sizes are becoming smaller and smaller as a result of progressive
individualization. The linchpin of optimal transport solutions are automated conveyor systems. Monitoring their condition,enhancing robots with vision systems, using a flexible, decentralized controls architecture and inline traceability help you toincrease OEE on your intralogistics application.

TRACE PRODUCTS WITH BARCODES,
2D CODES AND DMC CODESPREVENT DOWNTIME OF CONVEYOR MOTORSVISION GUIDED ROBOTS​

I/O FOR ISLANDS OF AUTOMATION

If a conveyor is at a standstill, products often cannot be
produced and packages cannot be shipped. Our Condition
Monitoring Tool Kit (CMTK) is the ideal solution for avoiding
such delays and the associated costs. It gives you deep insight
into the actual condition of your machinery and equipment,
allowing you to detect deviations and problems at an earlystage and intervene in time.

In applications where machine outputs are randomized andneed to be organized, robots are utilized for pick and place ofthe objects. This requires machine vision to determine an
item's presence and position on the conveyor. With a moving
conveyor tied to an encoder axis, the robot picks product on
the move, or the conveyor can be controlled so the parts are
picked from a stationary position. Generally, 3D cameras areused to provide the position feedback. By utilizing machine
vision for robot guidance (VGR), the robot knows what topick when.

Those who want to control the complexity of intralogistic
processes in greater detail are increasingly relying on
decentralized concepts. When handling parts and materials,
one network distributor used as a remote data compressor cantake care of multiple complex tasks: all analog functions, RFID
applications, valve control, signaling and use of remote I/O.
Whether you are bundling digital and analog signals, switchingpneumatics, recording and tracking data or want to display
operating conditions with the SmartLight signal tower light,
one IO-Link master per production segment is all you need.
Even better, our IO-Link masters with 4 A output current canbe used to control up to four drives and thus operate bothconveyor belt motors and electric stoppers on the roller
conveyors. The advantages: Reduced load on the control
system, pre-processing of information, increased productivity,and lower energy consumption.

1 CMTK Condition Monitoring Tool Kit
2 BCM Condition Monitoring Sensor
3 BAV Base unit

1 BVS 3D camera
2 BDG Rotary cncoders
3 BCC Power and network cables

1 BNI IO-Link sensor/actuator hubs
2 BIS data carriers
3 BIS read/write heads
with integrated processor unit

The new BVS IdentSensor expands the existing range ofstationary code readers from Balluff. Developed for the precise
reading of barcodes, 2D codes and DMC codes, it provides
simple and flexible communication interfaces to the process
and IT network. Modern, future-oriented programming
interfaces (REST API, MQTT) and dedicated industrial
interfaces (IO-Link, TCP, UDP) as well as additional condition
monitoring information make the sensor unique and ideal foruse in fast and difficult processes in automated production.

4 BNI SmartLight tower light
8 BVS IdentSensor
5 BNI IO-Link master6 BAE PS Heartbeat® power supply
7 BNI IO-Link valve manifold connector
www.balluff.com

Revolutionizing
in Packaging,and Beverage
Revolutionizing
OEE inOEE
packaging,food Foodand beverage| 31 | 31

Creating Success

CASE STUDIESWith a focus on improving production efficiencies in food and beveragefactories, machine builders and manufactures have implemented newtechnologies. A review of our partnerships over the decades shows theteams who have most effectively boosted productivity implemented one ormore of the previously mentioned applications areas into their equipment.
In many of the case studies presented here, the controls architecture
application area with IO-Link plays a foundational role in the value createdin the solution. The following real-world examples show how partneringwith Balluff and leveraging the application areas can dramatically improveavailability, expand performance and enhance product quality.
Controls architecture
Format change■ Smart sensors■ Quality assurance■■

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 33

SAFETY, CONTROL, CONFIGURE AND MONITORSIMPLIFY WASHDOWN MACHINE CONTROLS ARCHITECTURE

During its search for a solution to handle the safety system of its new VisionPak™
vacuum pack machines, CP Packaging also sought out smart factory concepts todrive efficiencies and growth. The company, a producer of horizontal form fill and seal
machines in Appleton, Wisconsin, needed tools to both protect its staff and allow
workers to configure, control, and monitor that system. IO-Link controls architecturefrom Balluff delivered the benefits of Balluff’s safety system solution and the efficient
handling and configuring of analog and digital devices into the system. Safety over
IO-Link solutions combine automation and safety to deliver more efficient production
while protecting staff and equipment.

To meet the demands of customers wanting smaller, more efficient machines that also meet all
washdown design requirements, Triangle Package Machinery Company sought two solutions in one.
The company, a Chicago-based producer of vertical form fill seal machines primarily for the foodpackaging industry, incorporated IO-Link controls architecture and sensors from Balluff into their
new Compact Sanitary Bagger (CSB) machine to simplify the machine and controls architecture.
The incorporation of IO-Link from Balluff allowed them to significantly reduce the footprint, improve
washdown features, and enable ease of maintenance in their latest modular machine design.

Controls Architecture
Case Studies
In machine building, costs can come from many
parts of the process — engineering, cabinet design,
cabinet build outsourcing, machine assembly and machinecommissioning, and more. Opportunities abound for cost
overruns and delays. With controls architecture utilizing
IO-Link, machine builders and in-house retrofits at
manufacturers benefit from easier development andengineering efforts. Time to build and commission
new equipment allows for more machines to be built
and more projects to be completed with the same
people and resources. Controls cabinets shrink insize and condensed machine footprints allow for
more production in less space.

www.balluff.com

Revolutionizing OEE in Packaging, Food and Beverage | 35

34 | Revolutionizing OEE in packaging, food and beverage

Format Change
Case Studies
The time spent on manual changeover of a production
line due to product changes, packaging changes or sizechanges can have a significant impact on the overall
efficiency and effectiveness of the equipment. Changeover
not only requires physical adjustments, but also needs aslow ramp-up to ensure proper configuration and productquality. Material jamming or waste product can cause longer
and unexpected downtime. Automation technology used informat change can dramatically reduce the downtime andlosses between production runs.

CHANGE PART VALIDATION WITH RFIDSIMPLIFIED SETUP FOR SIZE CHANGE

When Edson Packaging, part of the ProMach group, discovered their customers needed toreduce changeover time to allow for more size changes per shift, they developed servo adjust
automated format change technology. By using industrial RFID with this system, Edson
was able to eliminate potential human errors and reduce the machine changeover time fromthirty minutes to just five. The RFID system allows the machine to track and manage change
parts and recognize whether the proper tools are installed during setup. In addition, data suchas part descriptions, recipe information and tool management data allowed customers toshare tools between machines, automatically identify size change recipes, and incorporate
predictive maintenance.

With Triangle Package Machinery’s Compact Sanitary Bagger, the setup of the machine wassimplified using automation components for machine adjustments due to bag size being changed.
An IO-Link position sensor was added on the back-seal cylinder, which would have been costprohibitive using traditional analog sensors. By using a cylinder with a position sensor, Triangle wasable to redesign the back-seal assembly and simplify the set up, which requires the bag size tobe changed and the forming tube to be swapped out. In addition, this lets the operators to better
monitor the speed at which the bagger operates and the consistency of the seal time. Triangle
added a continuous sensor so customers can monitor the sealing time, a critical parameter, over
the whole range without needing to change the hardware configuration when the forming tube
is changed.

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 37

PLANT-WIDE IMPLEMENTATION OF INDUSTRY 4.0 CONCEPTS

COBOT GUIDANCE WITH PHOTOELECTRIC DISTANCE SENSORSOne of the largest ice cream producers in the world, Helacor S.A., sought
technology to enable their Industry 4.0 factory concept. They wanted to retrofit
existing equipment to produce more ice cream while also maintaining productquality and gaining deeper visibility into troubleshooting downtime. For this,engineers at Helacor chose IO-Link machine mount controls architecture.
This allowed them to dramatically reduce wiring and eliminated issues caused bycleaning processes that stemmed from damage to traditional I/O and junction boxes.
IO-Link also provided detailed information from a variety of smart sensors and smart
devices. They integrated this data into the SCADA system and developed predictive
maintenance practices. Through this process, Helacor improved production output,
enhanced visibility and reduced unnecessary downtime.

While automating manual processes for manufacturers struggling with large staff shortages, engineers
at Biuro Inżynierskie IEC set out to automate the insertion of chocolate bars into a flow pack machine.
Determined to improve this process, they developed a system utilizing two cobots. However, the BiuroInżynierskie team quickly realized a need for feedback. First, they needed to know how far into the box
the robot should go to pick-up the bars. Second, they needed to know what level must be sensed torelease bars into the magazine rails at the proper height. By utilizing IO-Link controls architecture andsmart photoelectric distance sensors, they were able to implement this robotic automation application
without costly additional input cards.

Smart Sensors
Case Studies
Automation technologies are bringing real value tomanufacturers interested in improving their efficiency, adding
flexibility and expanding visibility in the plant. Demand forfood and beverage products has grown in both variety of
product and style of packaging, creating a need for flexibility.
Smart factory solutions are more reachable than ever before,
with robotics automation, controls architecture and predictive
maintenance applications leading the way.

RevolutionizingOEEOEEininpackaging,
Packaging,foodFoodandandbeverage
Beverage || 39
39
Revolutionizing

Quality Assurance
Case Studies
Identifying manufacturing and processing errors as early as
possible is essential for high productivity. Continuous checks
during the production or packaging process are critical toprevent lost batches and improve OEE. Continuous checks
keep products that do not meet quality standards frommaking it as far as filling, packaging or shipping. Subpar
products, once identified, are then improved or discarded,
avoiding a possible recall. With the goal to reliably monitor
your products and processes, there are a wide variety oftechnologies available from sensors to machine vision toindustrial RFID systems that ensure continuous traceability
throughout the process chain.

ERROR PROOFING OF BAG FILLINGFORMAT CHANGE AND TRACEABILITY WITH RFID

PRO-ASSEM sp. Z o. O. is regularly asked by customers about automating quality control
measures. Manual inspection is time consuming and operators can fail to detect defects inthe product, possibly allowing defective product to reach the end customer. In this application,
the machine needed to use 50 % fewer operators and be 50 % faster while having 100 %control over the quality of the finished product: a foil bag filled with a liquid and cut to size.
By utilizing a combination of photoelectric sensors, and magnetic field sensors on the pneumatic
actuators, the design specifications were achieved, saving the customer time in inspections andincreasing the machine’s efficiency.

The quality requirements of the world’s premium chocolate manufacturers include not only the raw
materials and packaging, but they extend to the production process itself. LoeschPack sought amethod to reduce the time spent performing changeovers and increase the flexibility of the formatchange process. They wanted to ensure that the packaging machine would only power on when all
the right components are in the right place for the set recipe. To do this, UHF (ultra-high frequency)
RFID technology is used to read the presence of all change parts at once. This makes it easier toprevent mistakes because the differences are often small and difficult to see with the naked eye. In
addition to identification of the parts for format change, other data is stored on the RFID tag suchas service life, maintenance records, last operator, and previous cleaning cycle.

www.balluff.com

RevolutionizingOEEOEEininpackaging,
Packaging,foodFoodandandbeverage
Beverage || 41
41
Revolutionizing

Boosting efficiencies

TECHNICALCONSIDERATIONSWhen designing an automation application for packaging, food andbeverage applications, some key technology considerations must be
taken into account during the sensor and device selection process.
An understanding of the open standard IO-Link and machine vision
technologies are foundational to technical success. Additional concepts
like industrial RFID, condition monitoring and machine safety all play
an important role. Due to the special nature of food and beverage
production, we offer some considerations for how to address themix of automation and food safety for the best application outcomes.
What is IO-Link?
Industrial RFID
■ Condition monitoring■ Smart Automation and Monitoring System■■www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 43

WHAT IS IO-LINK?
Utilizing a widely accepted and open vendor neutral technology for point-to-point communication, IO-Link offers an architecturethat is fieldbus independent. Process data shows up as simple packets of bytes in the controller for easy integration.
The parameterization data allows the devices to be quickly configured using simple read/write commands, and best of all,there is no “sub-bus” to cause headaches, nor is there a new protocol to learn.

CAN I GET THAT SENSOR WITH ETHERNET?

USE YOUR EXISTING NETWORK ARCHITECTURE

There is a technology that allows for multiple intelligent
field devices to be installed on the industrial Ethernet
network without costly overhead. This technology iscalled IO-Link. With IO-Link you will use the existing
equipment infrastructure to connect multiple intelligent
devices to one IP address through a master/device
relationship.

IO-Link technology utilizes your existing network
Infrastructure. Addressing is point-to-point with amaster/device relationship.

M12 3-WIRE CONNECTION – POWER AND		COMMUNICATION

FOUR OPTIONS FOR SETTING THE PARAMETERS
OF AN IO-LINK DEVICE:

The digital signal is carried over pin 4 of a standard
sensor cable and 24V power is provided to the device
in a standard configuration. If required, the IO-Link
port can be used for a standard I/O point.

Option 1 – Controller Parameter Storage■ Store in a data-table in the controller■ Push by the controller to the device■ Store multiple configurations

Features■Features
Universal, similar to USB architectures
Typically one device per master port
■ All major PLCs and industrial networks supported■■

Features
Universal – Open vendor neutral standard(IEC 61131-9) that works with existing industrial
protocols■ Smart – Flexibility and visibility down to the individual
sensor with diagnostics and parameterization■ Easy – Simple maintenance and quick setup
of new devices■

High noise immunity due to the 24V-step
serial signal■ Utilizes low cost unshielded 4-wire standard
sensor cables■ Cable runs can be as long as 20 m■

Option 2 – IO-Link Master Parameter Server
Activate built-in parameter storage■ Store most recent parameters in the master■ Download automatically upon replacement
Option 3 – PC Storage with USB Master
Store on a computer or IT network■ Connect via USB to the device■ Download parameters manually■

Option 4 – Webserver Entry with IO-Link Master
Store as a list in a document or file
■ Connect via the webserver to the device■ Upload parameters manually■

UDP

Industrial Networking

IO-LinkDeviceWebserver Entry with IO-Link master

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 45

INDUSTRIAL RFID

CONDITION MONITORING

For more than 30 years Balluff RFID systems have provided customers around the globe with actionable data. In turn, theseorganizations were equipped with reliable information to make complex business decisions. Balluff RFID systems are designed forsome of the toughest environments and can connect to nearly any control network. With industrial RFID you can trace allprocesses in a production environment from raw material procurement to production to consumption and disposal. This brings
transparency to the production sequence, its framework, and the use of the raw materials. By implementing Industrial RFID
manufacturers improve machine throughput, increase visibility and control quality to improve OEE in the plant.

You are only as strong as your weakest link. By utilizing condition monitoring, you can monitor the status and health ofcomponents and auxiliary units like bearings, linear drives, fans, compressors, HVAC units, chillers, belts, remote pumps andelectrical cabinets. These devices have many places for potential failure: wear, friction, unbalance, particle accumulation, heat,humidity, displacement or collisions. With condition monitoring technology, the health of your plant, machine or component canbe understood. Improvements to production output, equipment OEE, and predictive maintenance can all be realized by utilizing
condition monitoring where critical components provide clues before failure.

MULTIPLE ARCHITECTURE OPTIONSMACHINE ACCESS CONTROLFOOD AND BEVERAGE PUMP MONITORING

CONDITION IN THE CONTROLS CABINET

Every RFID system requires three parts — a processor,
an antenna (head) and a data-carrier (tag). The specifictechnologies required for each application are based on
multiple factors: available physical space, PLC
specifications, washdown/chemical ratings, read/write
distance, information storage location, and the ability to
tag the asset to be traced. IO-Link head/processors arecommonly used in food and beverage applications as
they can combine into one network connection. Other
applications require more data, and a processor/headthat sits right on the industrial network is preferred. In themost complex applications, separate heads andprocessors are utilized to guarantee application reliability
and efficiency. In all applications, handhelds are used bytechnicians to track maintenance and support calls.
Thousands of tag options are available, and different
combinations of frequencies and controls architecture
can be utilized to create the best application to improvemachine changeover time or provide detailed lineage/
authenticity data.

Industrial RFID systems provide a controlled and tamper
resistant solution for limiting access to the machine.
Using RFID to differentiate between operators,
technicians, supervisors and engineers can restrict
access to certain maintenance screens or automaticallychange the views for the HMI or interface. Access control
is used for verifying the operator’s work times, tracking
regular maintenance or supervisor override status. Many
current solutions utilize physical keys for supervisor
override or maintenance calls, but keys are easily copied,
lost or shared by employees on the floor causing issues
and confusion.

Pumps are used to transport unpackaged product fromone part of the plant to another, for example from storage
tanks to mixing processes to the filling or bottlingmachines. Hundreds of pumps are used in a typical foodand beverage factory and are commonly critical to hitting
output goals and maintaining plantwide OEE objectives.
By monitoring the vibration and temperature condition of
the motor and pump, you can better understand thehealth of the impeller, monitor the presence of lubricant,or detect changes in the system before catastrophic
failures or downtime can occur. We can best understandthe status of this equipment when combined with flow
monitoring systems like pressure sensors.

Ambient monitoring inside the controls cabinet gives anoverall assessment of the health of the controls cabinet
and the environment the sensitive control components
might be exposed to. High temperatures prematurely age
electronic components, shortening the lives of devices
like power supplies or drives and causing downtime fromelectronic failures. At low humidity levels, electrostatic
discharge (ESD) is easily generated causing intermittent
interferences or malfunction in production processes.
At high humidity levels, possible condensation occurs
causing corrosion, rusting, or shorting of IP20
unprotected electronic devices, making it frustrating totroubleshoot intermittent issues. Monitoring the condition
inside the controls cabinet for these conditions allows forcorrective actions to be made before damage occurs.

IO-Link

All-In-One Processor

Multi-frequency Processor

Handheld
ID Badge

Reader

1
2

BCM Condition monitoring sensor​
BNI IO-Link master

3
4
5

BNI SmartLight indicator
BNI IO-Link I/O hub
BAE PS Heartbeat® power supply

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 47

GUIDED CHANGEOVER SOLUTION
Changeover processes on a plant can cost a lot of time if settings have to be changed and change parts exchanged throughpainstaking manual work – a method that is not only tedious but also prone to errors. The Guided Changeover Solution, on theother hand, makes format changes faster and easier, thus increasing your OEE. It saves you money and can be retrofitted
at any time, even on existing systems. Here is how it works.

Simple operator guidance

Changeover Time
Downtime
Production Output

PlannedOur software guides the operator step-by-stepthrough the format changeover process,from the configuration of different formats
to the start of production.​

Unplanned
Continuous
Monitoring

ShortenChangeover

Eliminatedwaste

Vertical
Ramp Up

Product A

Product B

time
Ramp
Down

Changeover

Waste

Bug Fix

Ramp Up

Typical format change process:With Guided Changeover Solution
the customer decreased theplanned and unplanned downtime,
reduced waste and virtuallyeliminated the ramp-up time.

The operator guidance can be shown on various
end devices, such as fixed displays or tablets.
You can also choose between different
languages for the user interface.

Immediate feedback
Our Guided Changeover Solution can be used in manyindustries and is particularly suited to the special requirementsof the food, beverage, cosmetics, pharmaceutical, andpackaging industries, especially if one or more of thefollowing applies:
Small batch sizes are produced, which means machines
and lines have to be changed over frequently.​■ Many changeover points are present, and the changeoverprocess takes a relatively long time.​■ The changeover process requires well-trainedand experienced employees.​■ Production lines with several machines tochange over are present.​■ The start-up process after changeover takes
a long time and produces scrap.​■

Balluff's Guided Changeover Solution helps you adjust length,
width and height settings for guide rails, for example.
Sensors provide immediate feedback on whether the dimensions
are set and set up correctly.​
Our RFID technologies are used to automatically detect thechangeover parts and ensure that the correct format parts arebeing used.​

Only when the current step has been
completed correctly is the next step displayedon the screen. Even employees with little
experience will succeed in making rapid format
adjustments, while downtimes are reduced
to a minimum.​There is no need for timeconsuming readjustments. Manuals and hightraining costs will be a thing of the past.​

To visualize the outcome, an LED stack light is attached to themachine or system, using a clearly defined color scale to allow
you to read the machine status.​​You create sets of step-by-step instructions directly in oursoftware. All of the tasks can be described in detail andsupplemented with your own pictures. Each step can be linked
to a sensor for which you define the target value. Creating thesteps is quick and easy--programming knowledge is not
required.​​​

A stand-alone retrofit solution, ready for use in
the shortest possible time
You will receive our software pre-installedon an edge gateway. The system is completely
independent of the company network and themachine control system, which means thatyou can start immediately with the formatchange setup.​This makes it easy to introduce our independent
retrofit solution without connecting to yourexisting IT infrastructure.​

www.balluff.com

Revolutionizing OEE in Packaging, Food and Beverage | 49

From the single machine to the overall process

OPTIMALPERFORMANCEWASHDOWN PLUS PROMISE
Page 49

SMART FEATURES AND DISTRIBUTED LOGIC				Page 52

FOOD SAFETY
Page 51

DEVICE HEALTH AND STATUS ​Page 48

LOOK AND FEEL
Page 51

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Revolutionizing OEE in packaging, food and beverage | 51

SMART AUTOMATION AND
MONITORING SYSTEM (SAMS)LOOK AND FEEL ​DEVICE HEALTH AND STATUS ​WASHDOWN PLUS PROMISE

The all-encompassing operating and configuration
concept of SAMS increases machine flexibility andavailability. The devices can be parameterized, configured
and even taught without contact, by using a tablet withstandard data profiles. This reduces machine damage
and production stoppages due to incorrect handling toa minimum. Even relatively untrained personnel quickly
find their routine using our consistently operable solutions
and can avoid errors.

You always have an overview of machine and equipment
health, since condition messages allow errors to bequickly detected and localized (i.e. condition monitoring).
This information is always available to you uniformly,
and directly – whether via the colored LED indicator
directly on the device or on dashboards for further
analysis (i.e. predictive maintenance). You can visualize
this information as graphics, represent it in charts, or
output it as reports. Now that you are informed about
each individual sensor, every machine and your entire
production, you can recognize trends and plan
replacement or optimize maintenance for just the righttime. Together with our powerful network technology
and cloud computing, this data makes intelligent
manufacturing and the Industrial Internet of Things (IIoT)
become reality. To this end an edge gateway and IT
level can be seamlessly linked.

Significantly longer service life and significant costsavings due to less maintenance are what you can
expect from all washdown components in the Smart
Automation and Monitoring Systems. They are designed
and manufactured specially to withstand the highdemands of cleaning processes. At home in extremely
harsh environments, they meet Ecolab requirements.
They are well protected from cleaning agents and water,
and with a rating of at least 1000 cleaning cycles, ourproducts far exceed the requirements for IP69K.

MaintenanceFailureFunction check
Power/Comm.

www.balluff.com

Revolutionizing OEE in packaging, food and beverage | 53

WEBSHOP AND ACCOUNT PORTAL

SMART AUTOMATION AND
MONITORING SYSTEM (SAMS)

Easy online shopping
Navigate through the collections or run a search
In addition to attractive, transparent pricing, Balluff’s webshop gives you the productinformation you need to work quickly and efficiently. You can access our entire product range
in just a few clicks.

SMART FEATURES AND DISTRIBUTED LOGICDATA ACQUISITION AND SOFTWARE

With their consistent design the housing, connector
and fastening of the components form a unit, so that
installation and connection are easily accomplished.
Additional functions such as temperature monitoring,
inclination detection, vibration monitoring, signal quality
display and/or operating hours counter turn devices
into data sources you can use for reliable operation ofyour equipment. Such features eliminate the need for
additional devices with a monitoring function, significantly
reducing your inventory levels. In addition, eachcomponent can be uniquely located within the system
by pinging.

The future of automation is increasingly interlinked anddigital. The growing diversity of technology, including in
the private sector, means the expectations of manyusers are increasing while the demands on industry rise.
Meeting these increasing demands necessitates themerging of traditional automation technology (OT)and information technology (IT). The increased useof software is the next logical step. We offer you IIoT
capable hardware and middleware in combination withpowerful software. This means you benefit from systemsolutions for the widest variety of requirements in yourproduction environment. You get solutions for condition
monitoring of your machines, for monitoring yourproduction equipment or systems for format change
management.

See real-time availability
See which parts are in stock and available forshipment the next business day
by adding them to the cart.
Find relevant order information
You can look up material numbers
and receive information on a
product’s country of origin, weightand customs tariff number with your account.

CHECK
STOCK

Attractive prices
Find low-cost solutions for all yourVibration max.
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Compare >=Value 1 internal temp
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All your account information is in one place
The My Balluff page gives you central access to your customer account.
New features also simplify your ordering process.

Set pin fuction:
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switch point alarm

View order history
Now use the order history to view your current
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Download quotes, invoices anddelivery receipts at any time.
5
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2
3
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6

6

Condition Monitoring Toolkit
Network interface with JSON or REST api
Condition monitoring sensor
Smart IO-Link sensors
SAMS with condition monitoring
Heartbeat power supplies

Track orders
Track your delivery and get information about
the current delivery date.
View and confirm quotes
Confirm individual quotes online. After you
confirm the quote, we will process the order.

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Revolutionizing OEE in packaging, food and beverage | 55

GLOSSARY
Controls architecture

An application area focused on the physical architecture of inputs andoutputs. Controls architecture also focuses on improving how different
data is communicated to the control as well as the plant monitoring
services. This is done through improvements in the machine connectivity
by the use of machine mount hardware and smart devices.

Conveying

The conveying application area is more than just moving products fromone place to the other within the facility. During conveying, products canbe identified, checked for quality, sorted, accumulated and moved to theproper location at the right time. Traceability/identification, vision/inspection,
object detection, condition monitoring and networking all play a role inefficient product movement and automated conveying.

Food safety

Food safety is an objective to keep food safe for consumption without
biological or material contaminants. This is important for automationconsiderations due to a need for food contact of some components.
Hygienic sanitary machine design and hygenic component design havean impact on automation product selection and design.

Format change

In this application area, there is a focus on how to use technology
to improve format changes through decreases in changeover timeor reduction of errors. Size change, changeover, recipe change are
all impacted by this. Manual format change uses rules or marks, guided
format change helps the operator with automation to setup properly
and automatic format change can eliminate human error entirely.

Level sensing

By engaging with this application area, production processes
dramatically eliminate errors. Level sensing uses sensors to provide
point-level indication of full or empty or uses sensors to provide
continuous level feedback to know the exact amount remaining
in a tank or container.

OEE

Overall equipment effectiveness (OEE) is a common measureof a production plant's or production line's or a machine's
output. Through a combination of improving availability,
enhancing quality and expanding performance, OEE can bedramatically improved with innovative automation technologies
reducing waste and improving yields.

Predictive maintenance

The application area of predicitive maintenance utilizes smart
factory principles and condition monitoring tools to receive
diagnostic/event data from devices and trend that data overtime with the objective to predict when maintenance activities
should occur and eliminate unplanned downtime. In contrast to
preventative maintenance which is periodic, predictive
maintenance monitoring is typically continuous.

Preventative maintenance

The regular and routine maintenance of equipment andassets in order to keep them running and prevent unplanned
downtime from unexpected equipment failure.

Quality assurance

As an overall plant strategy, quality assurance teams track
conformance to standards, legal requirements, record
keeping and monitor product quality. Automation is used to
identify and contain deviations while maintaining uptime andpreventing recalls. Error-proofing or inspections are used tomonitor the product quality while traceability solutions areused to track-and-trace in production material flow and workin process (WIP) tracking.

Retrofit

A machine retrofit typically utilizes existing mechanicalequipment and updates the controls or adds functionality to
the machine. The ultimate objective of the retrofit is to improve
the overall effectiveness of the machine without entirely
replacing or scrapping it.

RFID gateway

A high-frequency RFID communication module used forpoint-to-point connection or as a bus interference.

Robotics automation

Robots are a quickly growing investment in food and beverage
plants. This application area focuses on how secondary automation tools, sensors and I/O devices can dramatically improve the utilization of robots improving the project return on
investment (ROI).

SCADASupervisory control and data acquisition (SCADA) is asystem of software and hardware elements that allows
industrial organizations control industrial processes locallyor at remote locations.

Smart factory

Industry 4.0, Industrial Internet of Things (IIoT) and Smart Factory
are regularly used interchangeably to indicate plant projects
working toward improving efficiency, adding flexibility and raisingvisibility inside a plant with the end objective to increase OEE.
IO-Link and smart sensors support this objective by enabling
manufacturers with actionable data and information for their smart
factory projects.

Types of data

There are many types of data. In this guide we discuss 3 major
types of data generated by IO-Link devices: diagnostic/events
data, parameter data and process data. Process data is thecyclic data used by the PLC to run the machine. Parameterdata is the configuration setup of the device. Diagnostic or
events data are generated to provide warnings or clues forpredictive maintenance activities and expedite troubleshooting.

Washdown Plus

A Balluff standard that exceeds Ecolab and IP69K requirements.
Products with the Washdown Plus Promise are tested towithstand at least 1000 cleaning cycles providing significantly
longer service life and less maintenance and expense than
traditional sensors.

www.balluff.com

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Global project management

WE ARE THERE FOR YOU —EVERYWHERE YOU ARE

We are global
Wherever you operate, we can support you directly on site. We work closelywith machine and plant manufacturers, system integrators, planning offices
and maintenance companies to create a worldwide network of technical consulting, sales and after-sales services for you.

Project manuals and release lists
To ensure that your projects are handled smoothly, we compile product data
individually. You receive project-specific manuals and release lists. Your personal Balluff contact will provide you with support throughout the entire
course ofyour project.

Customized services
If you would like our services to be even more tailored to your needs, we canmake this possible: with personalized e-catalogs, application-specific productmodifications, holistic software and system solutions, and comprehensive
logistics concepts.
Do you have any questions? Contact us. We will be happy to assist you.

www.balluff.com

Revolutionizing
Revolutionizing OEEOEE inin Packaging,packaging,Food
food and Beverage
beverage | 59

Balluff

YOUR PARTNER FOR
SUCCESS IN AUTOMATION

Balluff is a leading supplier of high-quality sensor, identification and image
processing solutions, including network technology and software for all
automation requirements. Family-run for more than 100 years, the company
today employs about 3900 employees in 38 subsidiaries within sales,
production, and development locations worldwide, all of whom are committed
to your success. Together with our representatives, we guarantee thehighest quality standards in over 60 countries so that you always get the best.
We deliver innovative solutions to increase your competitive ability.
Our consistent digital orientation drives our joint progress, and our innovative
spirit factors directly into your success.
We adhere to our motto "innovating automation" as pacesetters of automation,refiners and new developers, and technical trailblazers. In our strategic
incubation programs (SIPs), we develop new sustainable business models
according to the lean startup principle. Open exchange with associations,
universities and research institutes also helps us in this process. In this way,
and in close contact with our customers, we create innovative industry
solutions for automation. In doing so, we dedicate ourselves not only tothe classic automation areas, but also to the development of digitalization
and IIoT applications for an increasingly digital and networked world.
We have the future firmly in view in everything we do. We plan with foresight,
handle resources carefully and offer you long-term prospects.
You can rely on us, our commitment and Balluff quality – all in the name of amutually beneficial partnership.

www.balluff.com

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Headquarters
Balluff GmbH
Schurwaldstrasse 973765 Neuhausen a. d. F.
Germany

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