PC-based control for a food capsule and pod packaging machine
Second Quarter 2025Editor's Choice
Electrical switching & drive systems & components
Founded in Fidenza, Italy in 1982, TME Packaging Solutions is known around the world for its packaging solutions, particularly for powdered food such as coffee capsules and pods. “TME was one of the first companies to produce packaging lines for single-dose products and is currently focusing on technologies for sustainable packaging,” says Alice Magnani, head of HR and marketing, and member of the founding family’s second generation.
With the Cialdy Evo, TME has developed a compact packaging machine for coffee, barley, tea and herbal tisanes in sealed paper filter pods and in single-portion bags. The machine precisely dispenses and fills up to 200 pods per minute, which are then sealed with the integrated sealing unit. “The special thing about this packaging machine is that the packaging process takes place around the pod that has just been formed,” explains Andrea Zuccheri, who is responsible for software engineering and automation at TME. In addition to higher productivity, the integration of the packaging and sealing process offers further advantages such as a smaller footprint. The compact automation components from Beckhoff also play a part.
All disciplines combined in one system
“We’re excited about PC-based control as an automation solution which is why we have fully automated our machines with Beckhoff technology,” explains Zuccheri. “PC-based control ensures a clear control architecture, saves space in the machine and also reduces installation, wiring and maintenance work.” TME has implemented the entire range of Beckhoff components, from CX series embedded PCs and CP-Link 4 remote control panels to numerous EtherCAT terminals, AX5000 servo drives and AM8000 servomotors with One Cable Technology (OCT).
“What’s more, EtherCAT ensures fast and synchronous communication with all components. Moreover, several applications can be integrated into a single control system, including PLC and motion control, visualisation and vision as well as external applications such as the management of additional devices. For example, users can access the labeller integrated via EtherCAT in the control panel using a browser to set the parameters for labelling.”
The decision in favour of PC-based control was also made due to the continuous innovations that Beckhoff offers machine builders like TME. “PC-based control offers endless possibilities in the design phase. If we have an idea, we’re certain that we’ll be able to implement it,” says Zuccheri. The system-integrated approach also makes it possible to divide scarce personnel resources between the various machine series. This has enabled TME to reduce the overall design, development and testing times for its machines.
“You can’t build flexible and truly open machines today without using a PC-based architecture,” he continues. With PC-based control it is possible to connect the machine to the internet, communicate with other machines or devices on a production line and also manage devices and systems from other manufacturers. All this comes with a standardised, scalable solution that can be upgraded to the latest available PC technology or a more powerful CPU at any time without having to adapt the application.”
Another argument put forward by Zuccheri is that, unlike other software platforms, the TwinCAT development environment is free of charge: “Our technicians are always able to access the complete development environment on their laptops. This means that they can carry out upgrades or software reconfigurations at our customers’ premises at any time.” In the event of acute faults, the end customer can install TwinCAT on a local computer and connect to the system within a few minutes. Using remote maintenance, the service technician can then search for and rectify the fault. “During the COVID-19 pandemic our support team was able to carry out commissioning and maintenance tasks on systems that were thousands of kilometres away,” he adds.
Investing in sustainability
According to the machine builder, system supplier Beckhoff optimises purchasing management and accelerates the implementation of innovations with its product developments. TME is currently focusing on sustainability, both in terms of reducing energy consumption and processing environmentally friendly materials. “Our upcoming machine series will be even more modular and open for integration – and will come with an app for monitoring,” concludes Zuccheri.
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