Machinery safety products and services for packaging machines

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Pilz Automation Technology has supplied PNOZmulti Mini configurable safety controllers and other machinery safety products to BVM Brunner for use in the company's latest servo-driven packaging machines.

Machinery safety products and services for packaging machinesPilz Automation Technology offers an extensive range of machinery safety products and services, many of which are suitable for use within packaging machinery, whether small, relatively simple machines or large, complex packaging lines and palletising stations.

One company that has benefited from Pilz products and services is BVM Brunner GmbH & Co KG, a manufacturer of film wrapping packaging machines. Having taken an early decision to comply with EN ISO 13849-1, BVM Brunner carried out renewed machine risk assessments in order to update the safety concepts on its machines. Following this, the company decided to implement a new safety design for one of its machines, which incorporated comprehensive, 'state of the art' safety systems from Pilz.

BVM Brunner's latest machine, the Compacta Genius Servo, is a fully automated machine with a continuous motion, cross-sealing jaw. A safety concept was required for this machine, which would not only safeguard the operator, but also complement the flexibility and easy handling required when processing a variety of products for different customers.

Safety system design

The Pilz Safety Calculator, PAScal, was used to determine the required PL (Performance Level) and SIL (Safety Integrity Level) of the safety functions according to EN ISO 13849-1. The PL and SIL requirements, together with the handling requirements, were then matched with the Pilz product range within the PAScal Calculator library.

The new compact configurable safety relay, PNOZmulti Mini, was selected to monitor safety functions. Despite its compact 45mm width, the PNOZmulti Mini with its 20 safe inputs and four safe semiconductor outputs (to SIL 3, PL e) covered all safety functions of the machine, including emergency stops, safety light barriers and safety gates (movable guards). The PC-based drag-and-drop PNOZmulti Configurator also minimised the time and effort required for the initial set-up and enabled individual configuration for different customers and products.

Existing mechanical safety gate switches were replaced with Pilz PSENmag low-maintenance, non-contact magnetic safety switches that offered high tolerances for set-up and switching distance, a clearly visible status indicator and reduced engineering time due to plug-in cables.

Regardless of the size and complexity of packaging machines, there will often be a need for other safety-related components. Pilz offers a wide range of products, including safety switches, safety bolts, optoelectronic safety devices (light curtains), camera-based safety systems and emergency stop switches.


In order to maximise the productivity of packaging machines, high-quality diagnostics are needed. Not only does Pilz offer a variety of operator displays that can convey relevant information to operators and maintenance engineers, but the company's PVIS 'intelligent diagnostics' technology provides plain text messages with precise information on the location of the fault, clearly defined responsibilities, as well as an integrated 'root cause' display. This ensures that production can be restarted quickly in order to minimise costly downtime.

Today, most packaging machines incorporate servo and motion control technology. The Pilz Motion Control (PMC) family covers motors, servo drives and motion controllers. The PMCprimo Drive, for example, combines the functions of a servo amplifier, motion controller and PLC in a single unit – with the added benefit of an integrated safe stop function. The PMCprotego offers even more safety functionality, including safe reduced speed, safe operational stop and safe brake test.

As well as safety products, Pilz is also a leading provider of machinery safety-related services, including training, engineering and consultancy. Depending on customer requirements, Pilz can undertake risk assessments, SIL (safety integrity level) determination, engineering design and/or validation of safety-related control systems and CE marking services. Training courses cover both the application of Pilz products and machinery safety standards, regulations and responsibilities, including a C&G certified Machinery Safety Course.

For more information about products and services for the packaging machine industry, email , telephone +44 (0)1536 460766 or go to

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