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.
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:
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.
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.
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.
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.
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.
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.
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.
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.
- Detection of PET preform / PRK 18B
- Filling level measurement / LS 55 H2O
- Presence control of bottle caps / HT 3C.XL
- Bottle detection during transport / PRK 3C, PRK 55, RK 18B
- Container detection for labeling / PRK 3C.T
- Cut mark detection / KRT, CRT
- Door monitoring / MC 300, RD 800
- Precise detection of positions / PRKL 3C
- Detection of conveyor load / HTU 318, HTU 418
- 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.
- Detection of transparent vials during infeed / LV 463
- Precise positioning of vials / PRKL 53
- Detection of vials in screw conveyor / HT3C.V
- Splice detection / VSU 12, IGSU 14D
- Cut mark detection / KRT 3B, KRT 55, KRT 18B
- Determination of trigger position / PRK 3C, PRK 55
- Label detection / IGSU 14D, GS 63B, GS 61
- Presence control of labels / LRT 8
- Code identification / DCR 200i
- 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.
- Monitoring of product infeed / HRTR 53.S
- Detection of front edge of product / HRTL 53.C2.XL
- Safeguarding of safety doors / S 420
- Mark detection on film / KRT 3B, KRT 55, KRT 18B
- Measurement of roll diameter / ODS 96B
- Detection of film end / RK 18B
- Evaluation of safety signals / MSI SR, MSI 400
- Monitoring of code printing / LSIS, DCR 200i
- Container detection / PRK 46C
- 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.
- Multiple-track object detection / LRS 36
- Product height monitoring / ODS 9
- Splice detection / VSU 12, IGSU 14D
- Web edge measurement / GS 754B
- Print mark detection / KRT 18B
- Monitoring of sealed seams / LV 463.XR
- Packaging content check / LS 25B High-Power
- Packaging content check / LCS-1
- Ejection monitoring / RK 46C VarOS, CSR
- 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.
- Code identification on packaging / DCR 200i
- Position and presence control of cartons / HT 25C, HT 46C
- Fill level monitoring / ODS 96B, ultrasonic sensors
- Closure control of packaging / LRS 36
- Detection of glossy objects / RKR 3B gloss
- Single-lane package monitoring / PRK 25C, PRK 55, PRK 8
- 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.
- Alignment monitoring for packages / CML in V-arrangement
- Monitoring of end positions / IS 244
- Foil detection / PRK 3C, PRK 25C
- Integration of safety sensors / MSI 400
- Interruption-free muting / RK 46C VarOS
- Access guarding / MLD-SET
- Access guarding / MLC 530 SPG
- Code identification / BCL 500i
- Pallet detection / RK 46C VarOS
- Detection of projections on palette load / CSL 710, CSL 505