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Solution Sets for Consumer Goods - Form, Fill and Seal

Community Manager
Community Manager
ctrlX AUTOMATION offers automation solutions for a variety of packaging applications for form, fill and seal machines

Example applications for packaging solutions

Package consumer goods the intelligent and efficient way

Nowadays, consumer goods such as potato crisps and chocolate bars but also non-food products need to be packaged and dispatched more and more quickly and cheaply. However, the high packaging speed must not be at the expense of sealing, which plays a key role in ensuring a longer shelf life and product safety. This requires supporting technologies that can speed up and automate packaging processes. 

By using automation solutions in packaging machines, manufacturers can increase efficiency: They can achieve faster production cycles and package more products per unit of time. This offers significant economic benefits. In addition, systems can be adapted to meet different or new packaging requirements much more quickly. Automation solutions also help to ensure consistently high quality by guaranteeing compliance with specific standards and requirements and minimizing errors in processes that were previously performed manually. 

With ctrlX AUTOMATION, Bosch Rexroth offers integrated, modular automation solutions for the packaging industry – and for consumer goods in particular. The open complete solution includes all hardware and software components for automatically controlling, regulating, monitoring and optimizing packaging machines, e.g. form, fill and seal machines. The automation toolkit provides hardware and software as well as services and offers a modular complete system which connects, controls and orchestrates all components. The package is rounded off with apps that are available as needed to expand the range of functions for applications in the packaging industry. 

New automation solutions for packaging machines 

The ctrlX AUTOMATION toolkit offers almost unlimited freedom and can provide drive as well as control and connectivity solutions in many areas of the packaging industry. One area of application is so-called form, fill and seal machines or flow wrappers with vertical and horizontal seals, i.e. VFFS (Vertical Form, Fill and Seal) and HFFS (Horizontal Form, Fill and Seal). The vertical version of the flow wrapper is particularly suitable for packaging products such as potato crisps, while the horizontal version can be used to package chocolate bars for example – at high speed and with reliable sealing. 

ctrlX AUTOMATION provides ideal support for both types of flow wrapper – in low range application (LRA), mid range application (MRA) and high range application (HRA) systems. 

VFFS - Vertical Flow WrapperVFFS - Vertical Flow Wrapper
In the smallest solution (LRA), the control system is integrated into the drive for the first axis. The other two axes are packaged in a double axis drive. The ctrlX CORE control system is connected to the decentralized ctrlX I/O and the ctrlX SAFETY system via EtherCAT. Sensors for temperature, contrast or the master axis encoder are frequently used in this type of application. Safe Torque Off is achieved with the help of discrete wiring. The web-based ctrlX HMI is also connected to the compact control system. The HMI server can run in the controller itself in combination with a web panel or on a Windows PC (e.g. panel PC) to optimize and safeguard the performance of the ctrlX CORE. This results in a space-saving, safe and economical overall solution for very high efficiency. 

If necessary, the solution can be expanded with additional components and scaled to meet the very highest requirements. The app architecture allows easy integration of Bosch Rexroth's own know-how and applications from Bosch Rexroth or third-party providers, for example in the field of motion and IoT. The ctrlX MOTION app and the Bosch DeviceBridge app are examples of these. 

ctrlX AUTOMATION was designed for simplicity. Bosch Rexroth allows easy engineering with intuitive usability. A ready-to-use, open application project for flow wrappers offers users numerous advantages such as: Starting the first project in just 10 minutes, up to 60% time savings during coding, increased code reusability, web HMI in a responsive design and open source code. 

The automation system is also future-proof and with “Security by Design” offers maximum security on all levels. Thanks to integrated IoT solutions, it even opens the door to the smart factory. 

ctrlX Configurator

With the ctrlX Configurator, you can design your automation solutions intuitively. The procedure for individually configuring them is easy, quick and reliable. The desired system topologies can be put together exactly as needed and retrieved 24/7. Go to ctrlX Configurator 

LRA form, fill and seal machine solution

Space-saving, safe and economical automation with integrated control system in the drive. 

Schematic example LRA solutionSchematic example LRA solution
Application example LRA solutionApplication example LRA solution
Configurator example LRA solutionConfigurator example LRA solution


ctrlX Configurator
LRA Solution | Form, Fill and Seal  | CTRLX350143

MRA form, fill and seal machine solution

A high level of flexibility thanks to integrated SafeMotion functions in the drive and ctrlX CORE in the embedded version, additional connection options to 3rd party controllers as well as the option of connecting the ctrlX I/Os to the ctrlX CORE directly without a bus coupler. 

Schematic example MRA solutionSchematic example MRA solution
Application example MRA & HRA solutionApplication example MRA & HRA solution
Configurator example MRA solutionConfigurator example MRA solution


ctrlX Configurator
MRA Solution | Form, Fill and Seal  | CTRLX635613

HRA form, fill and seal machine solution

Maximum performance and connectivity thanks to ctrlX CORE, numerous sensors and I/O Link integration, extended safety portfolio and clever combination of ctrlX DRIVE and IndaDrive Mi. Any extension of the application example possible by adding solutions from ctrlX World partners, e.g. WAGO, ifm or SICK. 

Schematic example HRA solutionSchematic example HRA solution
Application example MRA & HRA solutionApplication example MRA & HRA solution
Configurator example HRA solutionConfigurator example HRA solution


ctrlX Configurator
HRA Solution | Form, Fill and Seal  | CTRLX527634


The machine manufacturer ILLIG is helping to make the changing food packaging industry more flexible and future-proof by relying on the technological openness of the automation toolkit ctrlX AUTOMATION from Bosch Rexroth. “The modular approach is a good platform for developing future-proof machines,” said Markus Peter, head of electrical development at ILLIG Maschinenbau. “The open hardware and software modules ensure high process quality and allow us to obtain data which can be used to continuously improve productivity and energy efficiency.” Further information

Hi, I am Andreas and I work as a Business Developer for packaging automation. Contact me if you want to learn more about our ctrlX AUTOMATION packaging solution sets.
Editorial work by: KatjaX
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