Packaging automation with decentralized control architecture

In packaging manufacturing, increasing production speeds, system flexibility, and operational reliability are driving the adoption of more integrated automation architectures. Murrelektronik has outlined a packaging automation concept that connects all levels of the production system, from the control cabinet to field-level devices. The approach combines decentralized power distribution, industrial networking, machine safety, and edge computing technologies to optimize multiple stages of packaging operations within a unified automation infrastructure.

Integrated architecture for packaging production lines
Packaging production lines typically include multiple operational phases such as filling, conveying, quality inspection, robotic handling, case packing, and palletizing. Each stage requires different automation functions, but system performance increasingly depends on the integration of these processes into a single industrial communication and control architecture.

According to Murrelektronik, the objective is to reduce wiring complexity, simplify diagnostics, improve scalability, and increase machine availability by decentralizing automation functions closer to the field devices.

The company’s approach combines IO-Link communication, decentralized power supplies, industrial Ethernet switches, edge computing platforms, and integrated safety modules within a coordinated system architecture.

IO-Link connectivity for filling and dosing systems
In filling and dosing processes, signal integrity and process precision are critical for maintaining production consistency and minimizing material losses. Murrelektronik integrates IO-Link masters and hubs to provide communication between control systems and field-level sensors and actuators. These devices enable structured signal and power distribution while simplifying installation and maintenance operations.

The use of IO-Link communication also supports parameterization, device diagnostics, and predictive maintenance functions within packaging machinery.

Decentralized power distribution for conveyor systems
Internal product transport systems require continuous motor control and reliable power delivery across conveyor sections. For these applications, Murrelektronik uses decentralized power distribution based on the Emparro67 Hybrid power supply system. The solution distributes power directly on the machine, reducing centralized cabinet dependency and minimizing cabling requirements.

According to the company, this architecture improves energy efficiency, simplifies machine layouts, and reduces installation complexity in motor-driven roller conveyor systems.

Edge computing for robotic pick-and-place applications
High-speed robotic applications such as delta robot pick-and-place systems require low-latency processing and synchronized motion control. Murrelektronik integrates edge computing functions within its modular Vario-X platform, allowing logic execution directly at the machine level rather than exclusively in centralized control systems.

The company states that local processing reduces communication latency and improves synchronization performance in dynamic robotic applications.

Industrial networking for machine vision inspection
Quality inspection systems using machine vision generate large volumes of image and process data that require stable industrial network infrastructure. Murrelektronik uses Hybrid Xelity switches to support both industrial communication protocols and high-speed camera data transmission within inspection systems.

The switches are designed to maintain network stability and bandwidth availability during continuous data-intensive inspection operations.

IO-Link signaling and diagnostics in case erecting systems
Operator interaction and machine status visibility remain important factors in packaging line operation and maintenance. The Modlight60 Pro RGB signal towers incorporate IO-Link communication to provide bidirectional status reporting and diagnostic functions. The integration enables simplified wiring and centralized parameter configuration while supporting faster fault identification.

Robotic case packing and palletizing automation
Automated case packing and palletizing operations require coordination between robotic systems, transport equipment, and safety infrastructure. According to Murrelektronik, integrating these systems within a unified automation architecture improves process repeatability, reduces cycle times, and supports continuous operation in high-throughput packaging environments.

Safety integration in robotic cells
Industrial safety remains a critical requirement in robotic packaging applications. For robotic cell protection, Murrelektronik integrates decentralized safety modules such as the MVK CIP Safety Ethernet/IP module. The system combines standard and safety-related signals within a single field-level device.

This architecture reduces wiring complexity while enabling direct implementation of safety functions within the machine environment.

Unified automation ecosystem for packaging systems
Murrelektronik positions its packaging automation concept as a complete manufacturing ecosystem rather than a collection of individual automation components. The company identifies several operational advantages associated with this approach, including reduced cabling requirements, simplified installation processes, faster diagnostics, improved machine availability, and scalability for future production expansions.

As packaging manufacturers continue adopting digital manufacturing and industrial connectivity strategies, decentralized automation architectures are becoming increasingly relevant for integrating robotics, machine vision, industrial networking, and safety systems into unified production environments.

Additional Context: This section details technical specifications and competitive benchmarking not included in the original product announcement
The market for packaging automation infrastructure includes suppliers such as Siemens, Rockwell Automation, Phoenix Contact, Balluff, and Murrelektronik. Key technical criteria in this sector include industrial communication reliability, decentralized power management, machine safety integration, edge processing capability, and scalability for modular production systems.

IO-Link technology is increasingly used in packaging automation for sensor integration, diagnostics, and parameter management at field level. Decentralized automation architectures also reduce cabinet space requirements and simplify machine modifications in flexible manufacturing environments.

Edge computing platforms integrated directly into machine structures are becoming more common in robotic applications requiring low-latency motion control and real-time processing, particularly in high-speed pick-and-place systems and machine vision inspection environments.

Integrated safety communication protocols such as CIP Safety over Ethernet/IP are also gaining adoption in packaging and robotic automation systems to simplify safety wiring while maintaining compliance with industrial functional safety standards.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.murrelektronik.com