Go to home page
0 Watch/inquiry list
0 Comparison

More than you expect.
Packaging. Sensors. Solutions.

Automated systems for production and packaging processes need to be more flexible, more efficient and more intelligent. We help you with our innovative sensor solutions.
From the first to the last step in the packaging process.

The processing and packaging of food, pharmaceuticals or cosmetics places high demands on hygiene, robustness, speed and safety at work. Products and product packaging change continuously in automated packaging processes. For decades we have been working closely with manufacturers of packaging machines and with consumer goods producers from different sectors. Our industry experts have an exact knowledge of the special challenges and needs. Regardless of whether you require individual standard or special sensors, complete sensor solutions or have questions about Industry 4.0, predictive maintenance or safety at work. Our goal is to ensure that your packaging systems are available and the processes and products are safe and trackable.

You can expect more from us in the future

The development and integration of special sensors for challenging tasks in the packaging industry is our strong point. We have built up a reputation for it over many decades – and our customers benefit from our expertise. With our 25 series, for example, we offer the world's most powerful throughbeam photoelectric sensor, a dynamic reference diffuse sensor specially designed for detecting products and packaging on conveyor belts and a highly precise retro-reflective photoelectric sensor for detecting clear glass. These special solutions are based in an innovative, comprehensive range of series 25 products with more than 200 different product variants. It provides our customers with solutions for all packaging applications – from standard to special.

Our highlights for the packaging industry

The LS25CI photoelectric sensor is the most powerful throughbeam photoelectric sensor on the market and our problem-solver for penetrating films. It is so powerful that it can reliably penetrate even metalized packaging films.

A highlight for the packaging industry is our DRT 25C dynamic reference diffuse sensor. This sensor is equipped with intelligent "Contrast Adaptive Teach" (CAT) technology and specializes in detecting difficult shapes and surfaces. It detects flat to spherical-shaped products with the same level of reliability as transparent to highly glossy packaging materials – without the need for alignment at the sensor in the case of format changes.

The PRK 18B series retro-reflective photoelectric sensors are the ideal solution for detection applications involving very fast moving, highly transparent containers. The high-speed retro-reflective photoelectric sensor detects preforms and PET or glass bottles extremely quickly and reliably. A special tracking function compensates for contamination and increases the cleaning intervals.

The DCR 200i camera-based code readers in stainless steel housing (protection class IP69K) are specially developed for fast identification of 1D and 2D codes in food processing and packaging. Their compact design and intuitive operation enable them to be quickly integrated into different applications.

Our GS(L) 08B series fork photoelectric sensors with their robust, clean-room-compatible V4A stainless steel housing, ECOLAB certification and degree of protection IP67 are able to withstand particularly intensive cleaning cycles. A large product range with different fork widths and light sources (red light LED, laser-generated red light) enables flexible use in the pharmaceutical, food or cosmetics industry.

The GSX combined fork sensor combines the two detection principles of ultrasound and light in a single housing. It quickly, reliably and precisely detects labels of all types, regardless of their material and characteristics. The fork sensor can therefore be implemented extremely flexibly and is ideal for labeling machines on which various label types are used.

The range of series 53 and 55 sensors in stainless steel housing is designed for detection tasks in hygiene-sensitive production and packaging processes. The throughbeam and retro-reflective photoelectric sensors have been developed for specific demanding applications such as the detection of glass, aqueous liquids or films. Thanks to their high degree of protection IP69K, ECOLAB certification and extended CleanProof+ certification, the miniature sensors can be used in wet zones (WASH-DOWN design) and hygienic areas (HYGIENE design).

Access guarding on conveyor lines must prevent danger zones from being accessed by persons and at the same time allow the transported goods to pass through. To achieve this, the muting function bridges the safety sensor in a controlled manner so that transported items can pass through. In our MLD 300/500 multiple light beam safety devices and MLC 500 safety light curtains, the muting function is already integrated.

Further applications for the different areas of the packaging industry

Innovative sensor solutions for production and packaging processes

The processing and packaging of food, pharmaceuticals or cosmetics places high demands on hygiene and robustness. We support manufacturers of packaging machines and consumer goods producers with tailor-made sensors and automation solutions. 

Our sensors are specially developed for your tasks in the primary and secondary packaging as well as in the final packaging of food, beverages, pharmaceutical or cosmetic products.

Discover the whole world of packaging sensor systems from Leuze:

Object detection

Our optical sensors detect objects and packaging with a high level of stability and reliability. A large number of different light spots, operating principles, designs and sizes as well as different hygiene equipment enable flexible use.

Our optical sensors

Contrast and cut mark detection

Contrast sensors are developed to detect defined markings on objects during packaging processes. These contrast markers are located on film, bag and blister packaging or on labels.

Our contrast sensors

Filling level measurement

Reliably detecting the fill level of aqueous liquids in all types of containers is one of the most challenging detection tasks for sensor systems and requires extremely powerful sensor solutions.

Our throughbeam photoelectric sensors

Labeling

The packaging industry uses labels of various formats, sizes, materials, and textures that are affixed to products and packaging by means of labeling machines. Fork sensors detect labels reliably and ensure the high quality of label attachment.

Our fork sensors

Identification

Camera-based 1D/2D scanners read codes even while in motion and have a wide area of application. Various versions with different sizes, optics, protection classes IP 67 or 69K, speeds or interfaces are available.

Our compact scanners

Industrial image processing

Solutions for industrial image processing enable machines to "see" so that manual inspection tasks can be replaced or supplemented by the use of digital cameras and functions for digital image processing.

Industrial image processing

Safety for packaging

With a comprehensive portfolio to satisfy all safety requirements, we offer you complete safety, an efficient flow of materials, and maximum availability levels worldwide.

Safety at Leuze

Interview: Increasing efficiency in the packaging industry

 

 

Further applications

Sensor solutions for beverage filling

In filling machines, liquids are usually filled at extremely high speeds into transparent glass and PET containers. Processes which are performed so quickly that the human eye can no longer perceive them, combined with transparent objects are a particular challenge for sensors used in filling systems. Highly sensitive clear-glass sensors with a switching frequency of up to 5 kHz are able to detect transparent containers even at extremely fast throughput speeds. Thanks to our 3C and 18B series clear-glass sensors with their integrated tracking function, system downtimes caused by increasing soiling are a thing of the past. The sensors are designed for use in wet applications. They are watertight and robustly withstand the permanent cleaning processes. The plastic and metal housings with protection classes up to IP 67 and 69K guarantee maximum availability of the system.

 

  1. Detection of PET preform / PRK 18B
  2. Filling level measurement / LS 55 H2O
  3. Presence control of bottle caps / HT 3C.XL
  4. Bottle detection during transport / PRK 3C, PRK 55, RK 18B
  5. Container detection for labeling / PRK 3C.T
  6. Cut mark detection / KRT, CRT
  7. Door monitoring / MC 300, RD 800
  8. Precise detection of positions / PRKL 3C
  9. Detection of conveyor load / HTU 318, HTU 418
  10. Single track monitoring / IS 218

Sensor solutions for pharmaceutical packaging

The packaging process mainly involves tablets being packed in blisters and various liquids being filled into small glass and plastic bottles. Owing to the strict hygiene standards, stainless steel is often the only material allowed for the components used. Maximum safety requirements apply during the production and packaging of pharmaceutical products. To protect against falsification, code readers must guarantee 100% decoding. The DCR 200i bar code scanner reads all codes and ensures the traceability of the production and packaging process for all products. With its hygienic stainless steel housing, it is ideally suited to the demands of the pharmaceutical industry. The hygiene design stainless steel sensors of the 53 series use laser technology to reliably and quickly detect even minute vials. Many challenges involving the detection of self-adhesive labels in the labeling station can also be mastered: For example, the GSU 14D fork sensor can reliably detect virtually invisible clear-on-clear labels. In quality control, the LRT 8 luminescence sensor also reliably checks the presence of attached paper labels.

 

  1. Detection of transparent vials during infeed / LV 463
  2. Precise positioning of vials / PRKL 53
  3. Detection of vials in screw conveyor / HT3C.V
  4. Splice detection / VSU 12, IGSU 14D
  5. Cut mark detection / KRT 3B, KRT 55, KRT 18B
  6. Determination of trigger position / PRK 3C, PRK 55
  7. Label detection / IGSU 14D, GS 63B, GS 61
  8. Presence control of labels / LRT 8
  9. Code identification / DCR 200i
  10. Safeguarding of protective doors and protective covers / RD 800

Sensor solutions for meat packaging

The industrial processing of raw meat and other sensitive foodstuffs requires the highest of hygiene standards. Only regular and intense cleaning of all affected components guarantees perfectly hygienic products. The automation components used in this sector must withstand aggressive cleaning agents, high-pressure cleaning and continuous changes in temperature.
The housings of the sensors recommended below are made of resilient, food-neutral plastic or high-quality stainless steel. They are extremely robust and therefore ideal for use in the meat and food industry. The high degrees of protection IP 67 and IP 69K and the ECOLAB certification guarantee durability.

 

  1. Monitoring of product infeed / HRTR 53.S
  2. Detection of front edge of product / HRTL 53.C2.XL
  3. Safeguarding of safety doors / S 420
  4. Mark detection on film / KRT 3B, KRT 55, KRT 18B
  5. Measurement of roll diameter / ODS 96B
  6. Detection of film end / RK 18B
  7. Evaluation of safety signals / MSI SR, MSI 400
  8. Monitoring of code printing / LSIS, DCR 200i
  9. Container detection / PRK 46C
  10. Code identification / BCL 304i

Sensor solutions for confectionery and bakery production

In the automated production and packaging of confectionery and baked goods, the fragile snacks are processed safely and hygienically and packed into attractive packaging. The demands on sensor systems are extremely challenging: Standard sensor systems are often not enough to reliably check irregularly shaped products or fill levels. The packaging sector places great demands on the reading performance of the sensors. Depending on the application, a huge variety of packaging materials such as high-gloss printed foils and partially or fully transparent films have to be reliably detected by one and the same sensor. The LS 25B throughbeam photoelectric sensors detect contents while or after the products are packed in printed or laminated films and foils. Contrast sensors such as the KRT 18B ensure that the packaging is cut to the correct size. Remote calibration via IO-Link or user-friendly adjustment at the device makes product changeover simple. It allows the operator to find the ideal configuration for the respective packaging material quickly and easily.

 

  1. Multiple-track object detection / LRS 36
  2. Product height monitoring / ODS 9
  3. Splice detection / VSU 12, IGSU 14D
  4. Web edge measurement / GS 754B
  5. Print mark detection / KRT 18B
  6. Monitoring of sealed seams / LV 463.XR
  7. Packaging content check / LS 25B High-Power
  8. Packaging content check / LCS-1
  9. Ejection monitoring / RK 46C VarOS, CSR
  10. Dimension and position monitoring / LSIS 4xx

Sensor solutions for carton and container packaging

The secondary packaging protects the elaborate primary packaging – typically shrink-wrapped packages in the beverages sector and boxes for most other goods. To ensure easy transport and handling, the individual units are grouped into packages. The used sensors must guarantee safe and careful packaging as well as smooth onward transport. Retro-reflective photoelectric sensors and scanning sensors are usually used for product detection in the infeed zone. Depending on the requirements of the specific application, measuring sensors such as the ODS 9 are used for more complex tasks. Closure checks then guarantee smooth onward transport. The checking of attached bar codes using the DCR 200i ensures reliable identification during subsequent handling operations.

 

  1. Code identification on packaging / DCR 200i
  2. Position and presence control of cartons / HT 25C, HT 46C
  3. Fill level monitoring / ODS 96B, ultrasonic sensors
  4. Closure control of packaging / LRS 36
  5. Detection of glossy objects / RKR 3B gloss
  6. Single-lane package monitoring / PRK 25C, PRK 55, PRK 8
  7. Completeness monitoring on containers / LRS 36

Sensor solutions for palletization

End-of-line in factory automation refers to the transition from production to storage and transport logistics. The machines used are characterized by an extremely high level of automation with standardized processes. In addition, the machines must have optimum safeguarding in order to comply with all occupational health and safety regulations. The reliable identification of packages ensures a precise and fault-free flow of material. As far as the efficient and safe design of operational safety zones is concerned, the MLC SPG safety light curtains are streets ahead of comparable solutions because they enable space-saving and tamperproof muting without the need for additional sensors. The RK 46 VarOS retro-reflective photoelectric sensors supply interruption-free presence signals, even in the case of irregularly shaped objects or objects with openings such as pallets or cages. As sensors for interruption-free muting, they also do more than standard sensors, e.g. if gaps in the load are to be detected. The 25C and 46C series sensors reliably suppress interference caused by reflective films in order to ensure that the object is detected correctly.

 

  1. Alignment monitoring for packages / CML in V-arrangement
  2. Monitoring of end positions / IS 244
  3. Foil detection / PRK 3C, PRK 25C
  4. Integration of safety sensors / MSI 400
  5. Interruption-free muting / RK 46C VarOS
  6. Access guarding / MLD-SET
  7. Access guarding / MLC 530 SPG
  8. Code identification / BCL 500i
  9. Pallet detection / RK 46C VarOS
  10. Detection of projections on palette load / CSL 710, CSL 505



Application reports and downloads

Technology report: Absolute Hygiene

1 Oct 2023 | Packaging industry
Hygiene-sensitive production and packaging processes require sensors that meet the most stringent requirements. Leuze makes this possible with sensor series intended for the food industry and with its many years of application know-how.
Show post

When apples go swimming

22 May 2023 | Packaging industry
By the time an apple reaches the supermarket and the consumer, it has already been through many different processes: It has been picked, checked, stored, sorted and packaged. Few companies are as familiar with these processes as BayWa Obst GmbH & Co. KG. The company's main location for the sorting and packaging of pome fruit is located in Kressbronn am Bodensee. BayWa has had premises there since 1967. A glimpse behind the scenes is exciting for apple fans, but also from a production-related point of view because Leuze sensor technology is used at multiple points to enable the processes to function safely and efficiently.
Show post

Best quality, non-stop

10 Mar 2023 | Packaging industry
Beer lovers in South West Germany are familiar with these traditional brands: Dinkelacker, Wulle Biere, Schwaben Bräu, Sanwald, Cluss or Haigerlocher. They are all regional beer specialties, each with its own character, and are brewed by Dinkelacker. The family brewery has been in existence since 1888. It was founded by Carl Dinkelacker in the Tübinger Straße in the heart of Stuttgart. And it is still headquartered there today. The company has always placed great importance on the best raw materials. They form the basis for the quality of the beers - whether Kellerbier in a swing top bottle, top-fermented wheat beer or non-alcoholic Pilsner. This quality standard is also reflected in the technical components used in production. For this reason, Dinkelacker has long been relying on Leuze application know-how, as well as sensor technology that meets the most stringent requirements for reliability, robustness and hygiene
Show post

A real piece of the ice age, bottled

28 Feb 2022 | Packaging industry
"Untouched since the ice age" is not a marketing slogan, but a fact - a real piece of the ice age that still exists today: When the ice melted, immense amounts of water drained away into the rock of the Swabian Alp mountains. The earth shifting in an unusual way then caused this reservoir to be sealed off approximately 400 meters below the outside world. Since then, heavy layers of impermeable stone have prevented rainwater from seeping through to the reservoir and have protected it from all the environmental influences of our time.
Show post

Increase productivity, reduce waste

1 Feb 2022 | Packaging industry
In addition to the demands on productivity, high expectations of consumers and retailers weigh on food manufacturers and processors. They expect not only safe and qualitatively perfect foodstuffs. In addition to adhering to legal regulations, they increasingly require additional certifications from their suppliers. To simultaneously comply with the legal requirements, meet the standards of the retail chains and satisfy the expectations of the consumers, functioning automation technology is essential for food manufacturers and processors. This means: They need intelligent technologies and services to allow them to meet the high standards with regard to food safety as efficiently as possible, in compliance with guidelines and while making the most efficient use of resources.
Show post

SN Maschinenbau: Three tasks, one visualization

31 Jan 2022 | Packaging industry
Whether sauces, snacks or ready meals have to be filled and packaged, high throughput and quick format changes matter in the packaging systems and food industry – And to the highest standards of quality and hygiene, too. For this purpose, the sensors used have to be able to do one thing above all: meet high demands for power, flexibility and hygiene all at the same time.
Show post

Quality is the number 1 key to success

31 Jul 2017 | Packaging industry
The Bavarian dairy products and fruit juice producer Gropper is committed to quality – not only of the products that they produce and bottle themselves. When selecting their partners and suppliers the company also sets high quality requirements. They rely on Leuze electronic for the secure monitoring of dangerous processes. The manufacturer of optical sensors offers an economical and space-saving safety solution here, which keeps with the stipulated machinery directive requirements.
Show post

Packaging technology industry brochure (PDF, ~9 MB)
DE EN ES FR IT JA KO RU TR ZH