Filling Process
PRIMARY PACKAGING
In primary packaging filling processes, reliable detection of both container presence and fill level is essential to ensure product quality, hygiene and efficient operation of filling machines. Containers must be correctly positioned before dosing starts, and the fill level must be monitored accurately to prevent overfilling, underfilling or spillage.
Contact‑free sensing technologies enable secure filling processes by verifying container presence directly at the filling station and continuously monitoring the fill level of bulk, liquid or viscous products. This ensures precise dosing, stable cycle times and predictable performance in high‑speed primary packaging machines. This reduces product loss, minimizes downtime and improves overall equipment effectiveness (OEE).
Key benefits
-
Reliable container presence detection before filling:
Contact‑free sensors verify that cups, bottles, jars, bags, boxes are correctly positioned before the filling valve opens, preventing spills and protecting the filling system. -
Accurate fill‑level monitoring across products:
Continuous, non‑contact level measurement ensures consistent fill volumes for products such as yogurt, milk drinks, sauces, soups, or detergents—independent of color or container material. -
Hygienic and contact‑free operation:
Non‑contact sensing avoids direct contact with the product, supporting hygienic design requirements in food, beverage, and home‑care filling applications. -
Stable performance in demanding filling conditions:
Reliable detection is maintained even with foam, splashes, or changing product properties, ensuring consistent filling quality at high speed. -
Improved product quality and OEE:
Preventing overfill, underfill, and misfills reduces waste, minimizes cleaning cycles, and supports higher throughput and availability in primary packaging lines.
Diffuse sensors
- Series
- R090K
- Dimension
- 10.7 x 43.5 x 19.5 mm
- Interface
- PNP NO/NC
- Principle of operation
- Photoelectric sensor
- Principle of optical operation
- Diffuse sensor, Triangulation
- Special optical feature
- Background suppression
- Beam characteristic
- Focus, typical at 90 mm
- Light type
- LED Red light
- Light spot size
- Ø 4.5 mm at 60 mm
- Range
- 20...350 mm
- Connection
- Connector, M8x1, 4-pin
- Housing material
-
PC
PBT - Material sensing surface
- PMMA
- Operating voltage Ub
- 10...30 VDC
- Approval/Conformity
-
cULus
CE
UKCA
WEEE
Ultrasonic sensors with analog output or digital output
- Style Housing
- Ø 18 mm
- Interface
- IO-Link 1.1
- Switching output
- PNP/NPN NO/NC push-pull
- Connection
- Connector, M12x1-Male
- Housing material
-
Brass, nickel-plated
PBT - Material sensing surface
- PU foam/Epoxy resin/Glass
- Range
- 25...250 mm
- Switching frequency
- 25 Hz
- Approval/Conformity
-
cULus
CE
WEEE
UKCA - Ambient temperature
- -25...70 °C
- IP rating
- IP67
- Repeat accuracy
- ± 0.15 % FS
- Operating voltage Ub
- 10...30 VDC
Photoelectric distance sensors
- Special characteristics
- Washdown
- Series
- 23K
- Dimension
- 51 x 23 x 52.4 mm
- Interface
-
IO-Link: 1.1
PNP/NPN/Auto-Detect: NO/NC - Principle of operation
- Photoelectric distance sensor BOD
- Principle of optical operation
- Light time-of-flight
- Beam characteristic
- Collimated
- Light type
- Laser Red light
- Light spot size
- 5.5 x 7 mm at 5 m
- Range
- 100...5000 mm
- Accuracy
- ±0.6 % FS
- Repeat accuracy
- 0.024 % FS
- Resolution
- ≤ 5 mm
- Connection
- Connector, M12x1-Male, 4-pin
- Housing material
- ABS
- Operating voltage Ub
- 18...30 VDC
- Approval/Conformity
-
CE
cULus
Ecolab
WEEE
Diffuse sensors
- Series
- 6K
- Dimension
- 12 x 34 x 21.6 mm
- Interface
-
IO-Link-Device: 1.1.3
PNP/NPN/IO-Link: NO/NC - Input function
-
Key disable on/off
Same function as button - Principle of operation
- Photoelectric sensor
- Principle of optical operation
- Diffuse sensor, Measurement of light transit time
- Special optical feature
- Background suppression
- Beam characteristic
- Collimated
- Light type
- Laser Red light
- Light spot size
- 2 x 3 mm at 1.5m
- Range
- 0...1500 mm Adjustment range 100…1500 mm
- Connection
- Connector, M8x1-Male, 4-pin
- Housing material
- ABS
- Material sensing surface
- PMMA
- Operating voltage Ub
- 18...30 VDC
- Approval/Conformity
-
CE
UKCA
cULus
WEEE
Diffuse sensors
- Series
- 6K
- Dimension
- 12 x 34 x 21.6 mm
- Interface
-
IO-Link-Device: 1.1.3
PNP/NPN/IO-Link: NO/NC - Input function
-
Key disable on/off
Same function as button - Principle of operation
- Photoelectric sensor
- Principle of optical operation
- Diffuse sensor, Triangulation
- Special optical feature
- Background suppression
- Beam characteristic
- Divergent
- Light type
- LED Blue light
- Light spot size
- 10 x 10 mm at 150 mm
- Range
- 1...200 mm
- Connection
- Connector, M8x1-Male, 4-pin
- Housing material
- ABS
- Material sensing surface
- PMMA
- Operating voltage Ub
- 10...30 VDC
- Approval/Conformity
-
CE
UKCA
cULus
WEEE
Downloads
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SIMPLIFY PACKAGING AUTOMATION. BUILD DIGITAL-READY MACHINES