Products
Service & Support
Industries & Solutions
Company

Filling Process

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.

BOD0020

Photoelectric distance sensors

BOS02F8

Diffuse sensors

BOS029M

Diffuse sensors

BOS02EK

Diffuse sensors

BUS007E

Ultrasonic sensors with analog output or digital output

BOD0020

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
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
More product details
BOS02F8

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
More product details
BOS029M

Diffuse sensors

Series
R090K
Dimension
10.7 x 43.5 x 19.5 mm
Interface
PNP normally open/normally closed (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
More product details
BOS02EK

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
More product details
BUS007E

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
More product details

Downloads

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

EPREL - European Product Database for Energy Labeling

Free sample product

In order to add a free sample product to the cart we will need to remove all the normal products from the cart. Are you sure you want to continue