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Object detection in secondary packaging

SECONDARY PACKAGING

In secondary packaging processes such as cartoning, tray packing and case packing, reliable object detection is essential to ensure smooth material flow and to prevent missing or mispositioned products. Typical tasks include detecting cartons before closing, verifying product presence during grouping and confirming complete layers prior to case packing.

A scalable sensing approach allows packaging machines to handle standard detection tasks efficiently while also covering more demanding applications. Entry‑level photoelectric sensors provide a cost‑effective solution for carton presence detection, while advanced optical and ultrasonic sensors support high‑speed and challenging applications. This improves line stability, reduces downtime and increases OEE in secondary packaging lines.

Key benefits

  • Efficient detection for standard applications
    Entry‑level photoelectric sensors reliably detect carton presence before closing or sealing, ensuring that empty or misfed cartons are identified early in the process.

  • High performance for case packers
    Advanced optical sensors enable fast and accurate detection of products, groups or layers in case packing applications, even at high throughput and with challenging surfaces.

  • Reliable detection where optics are not suitable
    Ultrasonic sensors provide consistent presence detection regardless of color, transparency or surface finish, making them ideal for mixed, reflective or irregular packaging.

  • Improved line stability and reduced downtime
    Reliable object detection prevents empty cartons, incomplete cases and machine stops, supporting continuous and predictable secondary packaging operations.

  • Flexible and scalable sensor concept
    The combination of entry‑level, advanced optical and ultrasonic technologies allows packaging machines to scale from basic carton detection to high‑performance case packing without redesign.

BOS02JM

Diffuse sensors

BGL006Y

Fork sensors and angle sensors

BOS02JE

Through-beam sensors

BOS02K2

Diffuse sensors

BUS007F

Ultrasonic sensors with analog output or digital output

BOS02JM

Diffuse sensors

Series
R072K
Dimension
12 x 42.5 x 22.7 mm
Interface
PNP: NO/NC
Principle of operation
Photoelectric sensor
Principle of optical operation
Diffuse sensor, triangulation
Special optical feature
Background suppression
Beam characteristic
Divergent
Light type
LED, red light
Light spot size
Ø 9 mm at 60 mm
Range
0...350 mm
Connection
Connector, M8x1-Male, 4-pin
Housing material
PA 6
PA 6
Material sensing surface
PMMA
Operating voltage Ub
10...30 VDC
Approval/Conformity
cULus
CE
UKCA
WEEE
More product details
BGL006Y

Fork sensors and angle sensors

Dimension
10 x 70 x 88 mm
Fork opening
50 mm
Interface
Push-pull NO(PNP)/NC(NPN)
Principle of operation
Fork sensor
Principle of optical operation
Through-beam sensor
Beam characteristic
Divergent
Light type
LED, red light
Light spot size
Ø 1 mm Light exit
Connection
Connector, M8x1-Male, 3-pin
Housing material
Zinc, Die casting, black coated
PUR, PA 6.6
Material sensing surface
Glass
Operating voltage Ub
10...30 VDC
Approval/Conformity
CE
UKCA
WEEE
cULus
More product details
BOS02JE

Through-beam sensors

Series
R072K
Dimension
12 x 41.4 x 22.7 mm
Interface
PNP: NO/NC
Principle of operation
Photoelectric sensor
Principle of optical operation
Through-beam sensor
Beam characteristic
Divergent
Light type
LED, red light
Light spot size
Ø 70 mm at 2 m
Range
0...20 m
Connection
Connector, M8x1-Male, 4-pin
Housing material
PA 6
PA 6
Material sensing surface
PMMA
Operating voltage Ub
10...30 VDC
Approval/Conformity
cULus
CE
UKCA
WEEE
More product details
BOS02K2

Diffuse sensors

Series
R072K
Dimension
12 x 42.5 x 22.7 mm
Interface
PNP: NO/NC
Principle of operation
Photoelectric sensor
Principle of optical operation
Diffuse sensor, energetic
Beam characteristic
Divergent
Light type
LED, red light
Light spot size
Ø 40 mm at 800 mm
Range
0 m...800 mm
Connection
Connector, M8x1-Male, 4-pin
Housing material
PA 6
PA 6
Material sensing surface
PMMA
Operating voltage Ub
10...30 VDC
Approval/Conformity
cULus
CE
UKCA
WEEE
More product details
BUS007F

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, 5-pin
Housing material
Brass, nickel-plated
PBT
Material sensing surface
PU foam/Epoxy resin/Glass
Range
30...350 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
More product details

Downloads

  • SIMPLIFY PACKAGING AUTOMATION. BUILD DIGITAL-READY MACHINES
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Energy consumption labeling

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Contact us directly by phone: +46 31 3408630


Balluff AB

Gamlestadsvägen 2, B19
415 11 Göteborg

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