Packaging & End-of-line
Fachmann/Sectors/Packaging and end of line
Sector / Packaging and end of line

Protect every access to the machine
without stopping the end of line.

EN 415-10ISO 13849-1ISO 14119ISO 13855IEC 60204-1IEC 61643-11

A packaging machine has more doors than any other in the plant, is opened at every jam and every format change, and works at the end of a line that cannot wait. Machine builders are also required to document the safety level and deliver a panel that works on power grids they do not know. Fachmann integrates interlocks, area detection, safety logic and panel power under a single technical interlocutor, aligned to EN 415, ISO 13849-1 and IEC 60204-1.

Typical applications

Applications
in Packaging and end of line.

Packing and cartoning · Palletising · Pallet exit · Machine panel

Cardboard boxes on a roller conveyor in a packaging line
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Packers, cartoners and case erectors

The problem

A cartoner or flow-pack wrapper has ten or more doors and covers, and the operator opens one at every jam or format change. Mechanical switches go out of alignment with vibration, fail one at a time, and the technician ends up bypassing the troublesome one with a spare actuator. With several doors in series, nobody knows which one opened the circuit and the machine stays down while the fault is traced.

The Fachmann solution
PILZbackbone

PSENcode non-contact safety switches with RFID technology: they reach PLe per ISO 13849-1 and, in the uniquely coded version, accept a single actuator and do not allow re-teaching on site, so a spare actuator cannot fool them. With no mechanical contact, they do not wear with machine vibration. They come in three sizes, the compact slim ones with 22 mm mounting, with IP67 protection on the connector version and IP6K9K on the cable version, and diagnostics via three LEDs. They connect in series up to PLe, or each door to its own input through the PDP67 decentralised modules, without wiring each switch back to the panel. PNOZmulti 2 brings all doors and stops together in a software-configurable controller, with 20 safe inputs and 4 safe outputs, up to PLe. Each door is wired separately, so you know which one opened the circuit, and Profinet, EtherNet/IP or Profibus modules report status to the machine PLC and HMI.

Featured families
  • PILZ PSENcode non-contact safety switches
  • PILZ PDP67 decentralised modules
  • PILZ PNOZmulti 2 configurable relays
Standards
EN 415-10ISO 14119ISO 13849-1
Palletising robot with perimeter guarding stacking pails on pallets
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Palletising and depalletising

The problem

The palletiser moves heavy loads inside an enclosure the operator enters to fix a fallen layer, change the base pallet or restock slip sheets. The risk is someone being left inside out of sight of whoever resets the machine, or a door opening with the hoist or arm in motion. Emergency mushroom buttons along the pallet conveyors are far away right when they are needed.

The Fachmann solution
PILZbackbone

PSENscan laser scanner (3 or 5.5 m range): monitors the inside of the enclosure with 2 protection and 2 warning zones, and up to 10 switchable configurations. If someone is inside, the palletiser does not restart. PSENmlock on the access doors: coded bistable locking, IP67, preventing opening during the hazardous cycle.

IDEM SAFETY

Rope Pull switches: continuous emergency stop along the pallet infeed and outfeed conveyors, with manual or automatic reset depending on model. A single device replaces several mushroom buttons.

Featured families
  • PILZ PSENscan laser scanners
  • PILZ PSENmlock door locking system
  • IDEM SAFETY Rope Pull Switch
Standards
EN 415-4ISO 13855ISO 13849-1ISO 13850
Pallet exit on a roller conveyor with a safety light curtain
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Pallet exit with muting

The problem

The opening where the finished pallet exits cannot be closed with a guard: the load has to pass several times an hour. Through that same opening a person can walk in behind the pallet up to the hoist or arm. The usual solution is a barrier that is overridden every time the load passes; if muting stays active longer than needed, or is triggered by any object, the opening is left unprotected.

The Fachmann solution
PILZbackbone

PSENopt II Type 4 multi-beam photoelectric barriers for body protection, PLe per ISO 13849-1, with range up to 55 m and a housing robust against shock and vibration. When the risk assessment allows PLd, the same family offers the Type 3 version, with 170 mm resolution (0.2 to 15 m range) or 300 mm (10 to 55 m range). PSENopt II muting arms are set up in L, T or X configuration according to the pallet path; their sensors are continuously height-adjustable and withstand shocks up to 10 g. PNOZmulti 2 evaluates the muting sequence and allows passage only while the load crosses the opening: a person alone breaks the barrier and stops the machine. The PITsign muting lamp signals muting mode per IEC 61496, with outputs monitoring its own operation.

Featured families
  • PILZ PSENopt II Type 4 photoelectric barriers (body protection)
  • PILZ PSENopt II muting arms (L, T, X)
  • PILZ PNOZmulti 2 configurable relays
  • PILZ PITsign muting lamps
Standards
EN 415-4IEC 61496ISO 13855ISO 13849-1
Electrical panel fronts with push buttons and indicator lights on site
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Machine panel and power continuity

The problem

A packaging machine builder ships the same equipment to plants with 120 or 230 V grids, with frequent outages and voltage dips. A micro-outage reboots the PLC mid-cycle: position is lost, the machine is left with product half-wrapped and has to be reset by hand. A surge on the plant grid ends up in the PLC or HMI board, and the builder pays the warranty.

The Fachmann solution
CABURbackbone

XCSE power supplies: 24 Vdc with wide-range input, 85 to 264 Vac, from 10 to 960 W in the same series. A single panel design serves different markets and power ratings. XCSU DC-UPS: 24 Vdc DIN-rail uninterruptible supply with integrated battery charging, 10 to 40 A depending on model. It keeps the PLC and actuators running during a grid outage without a separate external UPS.

OBO BETTERMANN

V20 Type 2 arresters on the panel supply (up to 40 kA, 8/20 µs, modules replaceable without tools) and VF Type 3 next to the PLC and HMI, as the last line of defence against surges.

Featured families
  • CABUR XCSE power supplies
  • CABUR XCSU DC-UPS
  • OBO BETTERMANN V20 Type 2 arresters
  • OBO BETTERMANN VF Type 3 arresters
Standards
IEC 60204-1IEC 61643-11
Reference regulatory framework

Referenced
standards.

The safety design rests on the international ISO/IEC framework, which in Argentina is articulated with Law 19.587 on Occupational Health and Safety and its regulatory Decree 351/79, which requires protecting workers from machinery and equipment risks.

EN 415-10
Safety of packaging machines: general requirements.
EN 415-4
Safety of packaging machines: palletisers and depalletisers.
ISO 13849-1
Safety-related parts of control systems: Performance Level (PL).
ISO 14119
Interlocking devices associated with guards: design and selection.
IEC 61496
Electro-sensitive protective equipment: barriers, light curtains and presence sensors.
ISO 13855
Positioning of safeguards with respect to approach speeds.
ISO 13850
Emergency stop function: principles for design.
IEC 60204-1
Electrical equipment of machines: general requirements.
IEC 61643-11
Low-voltage surge protective devices: requirements and tests (Type 1, 2 and 3).

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