The Revolutionary Sensor for Aseptic Environments

Accurate, repeatable and reliable non-contact detection of vials in aseptic environments – SICK’s stainless steel sensors enable this.

XTREMA F2000 is the latest innovation in aseptic filling from IMA LIFE.

State-of-the-art constructive details coupled with consolidated and worldwide re-known filling technology make of the NEW XTREMA Series the latest technological breakthrough in aseptic filling. Designed with a modern modular concept, XTREMA gives the possibility to actively manage the production process by tailoring the different machine phases to the actual production needs. XTREMA F2000 is an in-line filling and stoppering machine with continuous motion positive in-line transport system. The machine is suitable for filling liquid solutions into cylindrical vials and for insertion of rubber stoppers. It can handle all vial sizes in the range from 0.25 to 100 ml. To make this masterpiece work, design engineers of IMA LIFE were looking for an accurate, repeatable and reliable non-contact detection of the vials. Additionally, the solution needed to be robust, easy to use and resistant to any chemical agent used for disinfection (vaporized hydrogen peroxide, alcohol, etc.)

SICK provided IMA their competence and experience in developing optical sensors of the highest performance and reliability. IMA is guarantying to his customers:

  • robustness, to increase machine efficiency
  • ease to use and parameterisation, to reduce changeover time
  • accuracy of detection

To maintain high quality standards SICK photoelectric sensors of the series W4S, made out of stainless steel V4A/316L with a scratch resistant front screen resistant to any chemical agent used for disinfection (vaporized hydrogen peroxide, alcohol, etc.), was the perfect sensor for IMA LIFE. The W4S sensors combine the best optical technology from SICK by using a “PinPoint” sender LED, the bright and linear light spot across complete detection range guaranties state-of-the-art detection, accuracy, performance very similar to those of a laser. On top of this is the sensor IO-Link ready giving the possibility to change and store sensor parameters in the controls of the machine supporting 21 CFR part 11.

Advantage:

  • Improve productivity
  • Reduce changeover time
  • Maintain high quality standards
  • Robust, easy to use and resistant to any chemical agent

The W4 stainless steel series assures robustness, to increase machine efficiency, using a stainless steel housing and scratch resistant front screen. It is easy to use and to parameterize. So changeover time could be reduced by the use of teach-in or IO-Link. The accuracy of detection maintains high quality standards. PinPoint technology enables this.

This is an application story from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
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InduSoft Used on Networked Operator Interfaces for Extrusion Control

More Bang for the Buck

McGoff-Bethune, Inc. chose InduSoft HMI software for a new series of extrusion control systems because it enabled the company to build powerful, inexpensive operator stations which can be integrated across a plant-wide network.

InduSoft delivered decisive technological and commercial advantages. Because InduSoft operator interfaces can run on the Windows CE operating system, the McGoff-Bethune workstations are diskless and do not rely on rotating memory. It is a powerful collection of e-automation development tools for Web based integration. Each workstation is able to acquire data directly from the extruder, download recipes from the plant server, and generate production and quality reports for plant management to review over the network.

These operator interfaces help contain costs, improve reliability and have rapid recovery after a restart. When evaluating software for this project, McGoff-Bethune decided that the InduSoft Web Studio delivered a lot of bang for the buck.

This is a success story from InduSoft.
Tri-Phase Automation is an InduSoft distributor in Wisconsin
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SoftPLC Produces a BioMass of Power

SoftPLC handles biomass electric power plant

In Northern California, SoftPLC controllers, Tealware I/O and Web Studio are used by Blue Lake Power in their biomass electric power plant. The plant was originally a coal-fired plant that has been converted to burn woody waste. It uses wood chips as its mains fuel source for a conventional boiler which powers a steam-turbine generator.

Four SoftPLC’s are used for material handling, for both the input fuel and the ash by-product conveyors, and for all of the process control. Hardbook CPU’s with remote Tealware I/O connected via Ethernet are used for all the systems. Web Studio is used for the plant SCADA system which includes a redundant server, several desktop client stations and two large LCD displays in the control room. Web Studio is also used as the HMI running on portable tablet PC’s by the maintenance crew.

The Blue Lake plant adds over 93,000 MWh of renewable power to California’s grid and provides significant economic and environmental benefits for the city of Blue Lake and the state of California. The plant’s fuel procurement plan improves forest health, reduces hazardous fuels, and provides stability to the woods industry and local communities.

This application success story is from SoftPLC
Tri-Phase Automation is a SoftPLC distributor in Wisconsin.
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Vertical protection for an automatic pallet lift

Challenge
A pallet lift that connects several floors in a production building is to be protected against unauthorized or unintentional access during operation. At the same time, it should be possible to insert or remove pallets from the lift without triggering the safety device. There was very little mounting space available on the lift.

Application Solution
The automatic pallet lift is protected using the S3000, the only safety laser scanner approved for vertical protection at the time of installation. The device was installed at a height of around 3 m directly on the frame of the pallet lift. The floor is used as the reference contour. Two protective fields, one behind the other, monitor the lift opening and detect the direction of travel. When a pallet is loaded, the S3000 safety laser scanner detects the pallet based on the geometry taught; the pallet is transported into the lift. A person will not have the same rectangular dimensions as a loaded pallet and is reliably detected because the geometry is different to the geometry known to the scanner. If a pallet is to be moved out of the “paternoster”, the protective field is switched so that a movement in this now reversed direction is allowed.

The pallet lift is reliably protected using the safety laser scanner, without hindering the flow of material. The evaluation of the object contour makes it possible to reliably differentiate between man and material. Also with the vertical protection, not just a protective field, programmed only once, is monitored, its reference contours are also checked continuously. If the device adjustment changes in operation, this contour will change and the S3000 safety laser scanner stops the machine.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Verifying security feature on package

Improve package security by verifying all cartons in-line and reduce complaints of point of sales

For security reasons, e.g. anti-counterfeiting, a carton is (pre) printed with an invisible security marking. Before the carton is leaving the packaging machine it has to make sure that the invisible marking is present and is containing the correct information. Otherwise the carton can not be verified as authentic in a later stage in the production, logistics or point of sales.

Luminescence sensors detect marks that are only visible under UV light. This is due to fluorescent substances contained in the mark, which convert the UV light into visible light. The reflected light beam is received by the luminescence sensor and evaluated.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Verification of presence of pills in blister packs

Avoid unplanned production stops by verifying all pills after filling

Missing pills in a blister pack is an indication of bad quality, and is critical and crucial for pharmaceutical products. Incorrect number of pills or incorrect size of pills may lead to danger to consumer health, and will in every case lead to consumer complaints.

The Inspector is an intelligent vision solution in an easy-to-use sensor package. No matter what blister pack that comes down the line, the Inspector is up to the challenge. Without programming, but parameterization of predefined tasks, the Inspector is made easy. You don’t need to be a vision expert to setup the system.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Verification of date code presence on the packaging

Avoid unplanned production stops by verifying all dates after printing.

The “best before” or “use by” date are dates that have to be on all food products. The absence, bad quality dates lead to production of packages that are wasted if detected before shipping or result in consumer complaints when they reach point of sales. Moreover this can lead to a danger of consumer health. The Inspector is an intelligent vision solution in an easy-to-use sensor package.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Synchronization of cycle on a bag forming, filling and sealing machine with CS8 color sensor

SICK Color Sensor synchronizes the packaging process on a bag forming, filling and sealing machine using only one color element in the printed image.  As a result print marks are not necessary.

A crisps manufacturer had the special requirement that he did not want any print marks and the related read strips on the rear of the crisps bag for appearance reasons.

This task can be performed by the CS8-1 Color Sensor from SICK. A color element in the packaging design was taught once using teach-in. Using a small, precise light spot the device moves over all colors on the film and always switches when it detects the color taught. As a result a print mark is not necessary, it is possible to switch using an element in the printed image. The machine is controlled in this manner and cuts reliably at the correct point.

The crisps manufacturer was able to optimize the design of the crisps bag thanks to the CS8 color sensor, that is the manufacturer was able to avoid print marks and read lines. The sensor is easy to operate, works at high speed (up to 6 kHz), has a robust metal housing and is flexible during installation thanks to its exchangeable optics.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Color detection and quality control

The perfect combination of contrast and color sensor technology: when producing cables or yarn, the KTS and KTX sensors from SICK detect even the most minor color and contrast difference thanks to the color mode. Even faulty, incorrectly dyed material is detected reliably and sorted out in time.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Packaging material, end of roll detection

A lot of packaging machines use packaging material on rolls. The moment the rolls is empty it has to be replaced. Replacing the roll when complete empty will stop the machine for a while and a smooth change over is not more possible. Replacing the roll to early would mean that too much packaging material stays on the roll which is wasted.

The line-sensor AT20 array sensor from SICK projects a line of light on the roll with packaging material. An optimum alignment related to the coil assures a maximum accuracy. The sensor detects the edges from the coil and the foil and sets the analogue output in relation to the edge of the foil. A switching output is set when the distance from the foil to is below a certain value.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote