I/O Technology for Flexible Machine Concepts

B&B Verpackungstechnik relies on modular machine concepts with decentralized I/O technology from TURCK – for greater efficiency, flexibility, and digitalization

B&B Verpackungstechnik GmbH in Hopsten develops bagging and end-of-line packaging machines and relies on a modular machine concept with decentralized I/O and safety technology from TURCK. By using robust IP67 modules directly on the machine, the company significantly reduces wiring costs and speeds up setup, commissioning and service. The new architecture creates the basis for end-to-end digitalization – including remote maintenance, scalability and efficient service worldwide.

Control cabinet-free wiring solutions are an essential component of the modularization strategy
The variety of TURCK I/O modules and the coverage of all required signal types were decisive factors
TURCK's consistent multi-protocol strategy also pays off in the field of safety technology
The bulky switch boxes at the top are gradually being replaced by decentralized wiring
''We save up to 240 electrician hours per machine.'' Tobias Emsmann, B&B Verpackungstechnik

Tradition meets innovation: B&B Verpackungstechnik GmbH in Hopsten manufactures highly specialized bagging and end-of-line packaging machines – tailor-made for customers worldwide. The owner-managed company stands for quality, flexibility, and creative engineering. But even in an environment based on decades of experience, technical change is indispensable.

Decentralized I/O modules as the key to modularization

Together with his team, Emsmann developed the new machine concept. Instead of central terminal boxes, decentralized I/O modules were to be installed directly in the machine environment. In its search for a future-proof automation solution, B&B initially remained manufacturer-neutral. Emsmann and his team specifically looked for I/O modules that capture signals directly in the field. They chose TURCK's robust IP67 TBEN-L and TBEN-S block modules, partly because of their Ethernet multiprotocol capability, as they support both Profinet and Ethernet/IP.

Ultimately, TURCK also impressed in terms of functional safety: the TBPN hybrid safety modules enable the flexible integration of safety-related Profisafe and classic Profinet signals on a single module – including IO-Link. "I approached the selection process independently of any particular manufacturer – and ended up with TURCK," explains Emsmann.

Up to 240 electrician hours saved per machine

The changeover was a major undertaking. But it was worth it: cable lengths were drastically reduced, troubleshooting was simplified – and, according to Emsmann, B&B now saves up to 240 electrician hours per machine.

The new architecture not only facilitates assembly but also transport and commissioning. In Hopsten, the machines are completely assembled, tested, and then disassembled into modules suitable for transport. On site, they can be quickly reassembled thanks to pluggable connections – without time-consuming rewiring. Technicians also benefit in the event of servicing: modules can be easily replaced without having to delve deep into the electrical system.

Flexibility through IO-Link and multiprotocol

Although every machine at B&B is custom-built, the company relies on consistent standardization. Macro projects in Eplan, modular assemblies, and uniform I/O modules help to manage complexity. Even with different control systems, the field cabling remains largely identical—an advantage for design, purchasing, and service.

Partnership on equal terms

Close coordination with TURCK was crucial during the modularization process – especially when integrating the safety modules and communicating with different control systems. "There were many small things that had to be coordinated between the software and hardware at the beginning. But once contact between the experts was established, things moved quickly," summarizes Emsmann. He is satisfied with the support:

What began with a packaging machine is now being extended to other machine types. Bagging machines and combination systems are also set to benefit from the decentralized architecture in the future. The experience gained from the pilot project is being directly incorporated into further development. The company is already testing new modules and technologies – for example, for decentralized protection or for controlling adjustment motors. Condition monitoring and energy monitoring are also planned. The goal is a fully digitized, flexible, and maintenance-friendly machine platform.

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