1 Introduction
The CPS modular equipment concept provides Bosch Packaging Technologies with an intelligent overall solution for pharmaceutical products, offering customized packaging, serialization, encapsulation, tamper-proofing, and anti-tampering features. SICK's DeltaPac multi-task photoelectric sensor safeguards the integration of packaging and traceability systems, achieving error-free counting of seamless product flow within the CPS packaging module. An example is shown in Figure 1.
Figure 1
DeltaPac is a photoelectric sensor (as shown in Figure 2) that accurately detects quantities in product flows such as packaging and corrugated boxes, even through opaque gaps between items. This capability is based on its proprietary Delta-S-Technologie technology: four PinPoint2.0 -LED-like laser sources detect continuously arriving stacks of packaging, while two high-precision energy scales each have two receiving elements to identify reflected light. The innovative SICK-ASIC chip technology, SIRIC, assesses the dispersion of reflected light, differentiating based on the varying surface and contour reflection characteristics of the packaging and corrugated boxes. Simultaneously, an integrated distance detection system reliably shields against potential background environmental influences. “In this way, we can accurately identify (opaque) gaps with edge contour radii ranging from 1mm to 20mm within a distance of 30mm to 40mm,” said engineer KnutHelmer, SICK’s key account manager for the consumer goods industry in Düsseldorf. Therefore, DeltaPac can accurately count every carton in a seamless product flow. "This, in turn, enables the integration of packaging with a fundamental physical connection to traceable packaging levels such as strapping, shipping boxes, and pallets, and more importantly, an informational connection," said Daniel Sanwald, CPS Product Manager at Bosch Packaging Technologies Ltd.
Figure 2
2. Bosch Packaging: A Leader in Pharmaceutical Packaging Line Solutions
As a leading supplier of process technologies and packaging solutions, Bosch Packaging Technologies' pharmaceutical products division in Weiblingen, Germany, provides comprehensive solutions for pharmaceutical packaging, serialization, encapsulation, and tamper-evident seals. Within the broader concept of product traceability, Bosch Packaging Technologies focuses on developing multifunctional units that integrate printing, inspection, weighing, anti-counterfeiting labeling, tamper-evident seal protection, and packaging products into manageable and transportable units. Bosch Packaging Technologies' CPS product line enables customers to achieve modular, interconnected packaging line solutions capable of processing up to 400 corrugated boxes per minute. "The modular printing and control system meets all standards and complies with global laws and regulations regarding pharmaceutical industry identification, serialization, and corrugated box encapsulation," explains Daniel Sanwald. "Currently, regulations are particularly stringent in Turkey and China – these two countries have established regulations requiring 100% traceability of medicines from production to the point of receipt by the patient." Therefore, process stability is paramount—DeltaPac is the ideal solution for CPS encapsulation modules.
3. Superior gapless counting
In continuous flow of goods, the detection and counting of packages is essentially done by standard photoelectric sensors. However, "generally" a mechanical separation is still needed—that is, creating a light-transmitting gap between packages—to make more reliable identification of the front edges. "This affects the continuity of the product flow because it can lead to collisions or product stacking. If there are omissions in the packaging grouping or discrepancies in the quantity on the pallets, then the accuracy of serialization cannot be guaranteed, and only a huge expense can achieve this," says Daniel Sanwald. "In addition, a more compact, monolithic packaging transport saves more space for the packaging module." It is the advantage of DeltaPac that makes it applicable, as it can accurately identify individual packages in a seamless flow of goods. "Compared to the solution of vision systems, the advantage of multi-task photoelectric sensors is that if the shape, outer surface, or geometry changes, there is no need to readjust its settings," says Knut Helmer. Daniel Sanwald added, "This is a significant problem in practical applications if packaging changes are frequent." SICK's DeltaPac is a photoelectric sensor that, in Bosch Packaging Technology's CPS system, can accurately count the correct number of packages during seamless product flow, as shown in Figure 3.
Figure 3
4DeltaPac: Globally Innovative Technology, Unique Applications
In terms of its working principle, DeltaPac utilizes the edge contours of packaging and corrugated boxes. Four PinPoint 2.0 LEDs emit a laser-like light source that illuminates the front of the object. In this case, the four receivers on two sets of high-precision energy scales receive an equal amount of light, thus maintaining a balance of reflected light. When it reaches the edge of an object's front, only one light beam passes through, and this balance is disrupted. Once the intensity distribution of light energy on the receivers becomes uneven, the energy scale becomes unbalanced, just like a regular scale. The object's contour thus creates a distinct energy signal. DeltaPac accurately identifies this energy signal generated by the change in the direction of reflected light and then issues a corresponding switching signal. DeltaPac's high-precision sensing and evaluation performance ensures accurate detection even of extremely subtle angular changes, such as very small corners, radii, or channels. At the same time, bonded edges are suppressed. "Furthermore, this detection method does not misidentify any known interference factors because it actively utilizes color, outer surfaces, and background during setup," explains KnutHelmer. "Glare, contrast variations, surface irregularities—including electromagnetic interference in the operating environment—will not negatively impact DeltaPac's detection accuracy." Exceptional functionality combined with ease of use: DeltaPac is a global technological innovation with unique device technology applications. (See Figure 4.)
Figure 4
5. Ensure product and process stability across all packaging levels.
The CPS corrugated box printing and inspection system completes the entire primary packaging process—from capsules or tablets to bottling or blistering—providing the pharmaceutical industry with highly adaptable serialization solutions. “Using the CPS1900 with its inspection scale and tamper-evident features, we've shaped the entire serialization process,” says Daniel Sanwald, referring to Bosch Packaging Technologies' high-end solutions. If the medicine (capsules or tablets) is pre-filled in a marked, transparent plastic shell, it will be packed into a corrugated box during the first stage of assembly. These medicines are then re-inspected in the CPS labeling module and given a unique, sequential serial number. The next tamper-evident module affixes a transparent, perforated tamper-evident label to the insertion point of the tamper-evident flap. “This tamper-evident label is used to prevent tampering with the corrugated box and must indicate whether the packaging has been opened or is still brand new,” says Daniel Sanwald. After the packaging has been confirmed as marketable and secure, the next step in the sealing module is the bundling of the boxes—both physically and informationally. Here, they are identified by DeltaPac and read by an image-based barcode reader, the Lector620. Bosch's packaging technology has cleverly integrated both sensors into an aesthetically pleasing stainless steel housing within the encapsulated module – "for aesthetic reasons," Danielanwald emphasized, highlighting this design's strong focus on visual appeal from an industrial design perspective. See Figure 5.
Figure 5
DeltaPac counts the number of packages bundled together by detecting the frontal contours. The bundled packages are then placed onto the next robotic module according to the pre-set quantities by the control system, and an outer packaging is added. "Without DeltaPac, this automated, seamless sealing process would be completely impossible," recalls Daniel Sanwald. Now, manual operation is only required when each package is individually scanned and placed into the next sealing unit. The entire outer packaging is transported to a stacker crane. "Every sealing step is seamlessly inspected," says Daniel Sanwald. "The ERP system generates a pyramid-like complete sealing structure, including all bundling levels, achieving seamless traceability." Using DeltaPac ensures the highest reliability of the package identification and accurate counting process, and allows for continuous monitoring at all times.
This allows for product traceability throughout the production, packaging, and transportation processes. SICK's LECTOR620 product series, based on image-based barcode readers, activates the DeltaPac photoelectric sensor during the packaging process, as shown in Figure 6.
Figure 6
6DeltaPac supports easy integration of extended package modules.
Following the modular configuration of CPS, Bosch Packaging has also designed solutions that integrate packaging functionality as a separate component for packaging lines. "This allows us to provide packaging modules to existing packaging machines as extension packages," Daniel Sanwald points out, highlighting an interesting market. This provides a clear advantage for sensor technology; DeltaPac can easily and flexibly adapt to different requirements, offering tailored operating principles for sensor integration and packaging machine production.
The sensor is designed to meet a variety of specific needs, including Industry 4.0 requirements. Preset parameter versions are particularly suitable for rounded, diamond-shaped, or round packaging, as well as corrugated boxes with right-angled edges. This ensures maximum flexibility to adapt to diverse detection requirements. Installation, connection, and detection—system integrators won't need to search for operating instructions or manipulate some unknown switch on the sensor when expanding package modules or implementing highly diverse products.
To count packages in a seamless flow of goods, individual optimization of equipment parameters is required, making the DeltaPac sensor with IO-Link a viable option. "Using SICK's proprietary SOPAS-ET software, the DeltaPac can be tailored to specific needs through this interface," says KnutHelmer. "By inputting data such as package diameter, package width, and conveyor speed, sensor parameter settings can be easily configured for various application conditions, such as different types of packaging."
7. Reliable packaging, serialization, and encapsulation are achieved using SICK sensing technology.
DeltaPac's innovative detection concept has enabled Bosch Packaging Technologies to develop the most flexible, compact, and process-stable packaging modules. "In addition to this multi-tasking photoelectric sensor and the previously mentioned Lector® 620 barcode reader, a range of other SICK sensors also have a place in CPS systems, such as the AFS60 EtherCAT absolute barcode reader, the IDM160 series handheld scanner, the UF-next ultrasonic slot sensor, the WTB4-3 photoelectric switch, the new Glare gloss sensor, and the IME08 series inductive proximity sensors," Knut Helmer summarized. All products share a common lineage and are trustworthy thanks to the SICK global network service—not only for the sensor's performance—but also for the example of leading global equipment manufacturers like Bosch Packaging Technologies.
