41 www.drivesncontrols.com January 2026 PACKAGING AND PRINTING n programming language. This is not the case. All vendors support all IEC 61131-3 languages, meaning any of the standard’s graphical languages (LD, FBD, SFC) or textual languages (ST, IL) can be used on any platform. The choice of programming language(s) is left to the OEM, allowing the machine's logic to be implemented entirely in graphical ladder logic, structured text, or a combination of both. This potential variation clearly provides a challenge for engineers to understand and maintain multiple systems. The case for unification Believe it or not, unification isn’t about choosing a single control vendor. It’s about standardising interfaces and data so that packaging equipment from different suppliers can work together seamlessly on the same line. In practice, this often means adopting vendor-agnostic standards and communications methods. For example, Packaging Machine Language (PackML) is a standardised architecture that defines common states, modes and PackTags for packaging machines. This enables consistent control, easier integration and simpler maintenance on automated lines. Similarly, the Weihenstephan Standards (WS) provide universal naming conventions for PLC variables. They can also help engineers to gather data rapidly from machines because standard data points, such as power consumption, are consistently named and typed across systems. They are uniform, regardless of whether they are from different machine buildings or use different automation technologies. 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. Functions such as HotConnect and network bridging enable modular machines to synchronise and exchange real-time data accurately without relying on additional non-deterministic network layers, such as OPC UA. EtherCat’s detailed diagnostics can also help to identify cable breaks or EMC interference rapidly on a machine or line, helping to cut costly downtime. 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 massproduced 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. While this isn’t true lot size one (because many multiples of each name were produced), the campaign demonstrated successfully how personalisation can elevate the customer experience. With increasing market saturation, it is harder than ever to build brand awareness and loyalty, so the new levels of personalisation and “premiumisation” that are possible with lot size one are seen as a key market differentiator. It also allows manufacturers to capitalise on evolving e-commerce channels where directto-consumer sales allow customised products tailored to the consumer’s preference and increase further promotion via customer’s social media. Serialisation At the heart of this vision is serialisation – the ability to assign a unique identifier or code to every single item. This concept is already widely used in the pharmaceutical and food industries for compliance and traceability, and is becoming more common for consumer goods, too. Ultimately, serialisation is what makes personalisation, seasonal editions and SKU-level traceability possible. To make lot size one and serialisation visible at scale, packaging lines need 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. At the same time, packaging machinery must be able to handle complex demands while being intuitive enough for operators with more limited skills to use. PC-based control offers a flexible, open approach to industrial automation that can bring significant benefits to packaging lines. Unlike fixed-function PLCs, industrial PCs (IPCs) are built with industrial-grade components and a rugged design, and are optimised for real-time automation tasks and long-term availability. They support an open OS philosophy, allowing the seamless integration of third-party software and existing IT expertise 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 communications strategies. For example, Beckhoff’s 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 any hardware limitations. EtherCat networks complement this approach by delivering real-time communications and detailed diagnostics. They can detect issues such as cable breaks, node failures or electromagnetic interference automatically, allowing engineers to pinpoint and resolve problems quickly before they cause unplanned, costly downtime. Beckhoff’s TwinCat software further strengthens this PC-based approach. For OEMs, it 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 set-ups without requiring deep knowledge of the software. As well as troubleshooting, PC-based controls support modular, adaptable line designs. 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 simply having fast machines – they need unified, PCbased control, seamless communications 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 personalised production.n Beckhoff has produced a brochure called Highly efficient, flexible and resourceconserving: PC-based control for the packaging industry. It can be downloaded via https://drivesncontrols.news/9v9pjt4c The trend in packaging is towards personalisation, customisation and premium experiences
RkJQdWJsaXNoZXIy MjQ0NzM=