Decentralised signal processing with the Schmersal Safety Fieldbox

Packaging machine manufacturer Meypack relies on Schmersal's Safety Fieldbox for safety-related signal processing. This concept benefits not only the designers, but also the users of the machines.

26 January 2026

Packaging machine manufacturer Meypack relies on safety-related signal processing with the Safety Fieldbox from Schmersal. (Image: Schmersal)

Decentralised is best: Packaging machine manufacturer Meypack structures its safety-related signal processing according to this principle. The company relies on the Safety Fieldbox from Schmersal. This concept benefits not only the designers, but also the users of the machines.

Whether it's „one-portion sachet soups“, the growing pet food market, shampoo bottles or five-litre containers for the food service industry: Meypack, based in Nottuln, Münsterland, designs and builds automated systems for the secondary packaging of food, personal care products and other consumer goods for global players. The systems are always configured specifically for each customer and project. The integration into the Italian Aetna Group in 2022 will enable Meypack to tap into additional international markets.

Standardisation on the safety gate

Even though the systems are always customised, Meypack is focusing on ever greater modularisation and standardisation at the functional and component level: this makes special machine construction economical. This also applies to machine safety. Wherever safety doors are locked, the Meypack designers use the AZM 300 solenoid interlock from Schmersal. Among other things, it offers the advantage of flexible installation, enables thorough cleaning thanks to the high protection class IP 69 and is particularly suitable for the high requirements of hygienic applications.

The safety-related signals are collected decentrally via the Safety Fieldbox. (Image: Schmersal)

Meypack is also driving forward modularisation at the level of safety-related communication - with the Safety Fieldbox from Schmersal, which enables the simple connection of up to eight safety switching devices via plug and play. Using the universal device interfaces for eight-pin M12 connectors, the user can integrate electronic and electromechanical solenoid interlocks, sensors, control panels, light curtains or switches into the safety circuit. Solenoid interlocks or safety light curtains only require one M12 slot. This creates a good basis for the modularisation of safety technology - also from a cost perspective, as this universal device interface is more cost-effective than individual devices with a bus interface.

(Image: Schmersal)

„Originally, we collected the signals - including the safety-related ones - in decentralised terminal boxes and forwarded them from there. We also wired the emergency stop consoles individually to the control cabinet. This required a great deal of effort, which is no longer necessary with the safety field boxes. We benefit from this time saving in several ways, because we first assemble, test and approve the system completely in Nottuln and then dismantle it into modules for transport to the customer and reassemble it on site.“

Jörg Peikenkamp, Team Leader Electrical Hardware Design at Schmersal

Design engineers - and users when using the systems - also benefit from the fact that the safety switching devices can be individually configured via the safe ports of the Safety Fieldbox.

Simplified diagnosis

From Meypack's point of view, another reason for using the Safety Fieldbox is the improved transparency. An integrated digital input at each device slot allows the diagnostic signals of all connected safety switching devices to be analysed. In addition to the safety-related signals, the operational signals, e.g. those required for diagnostics, are also collected and transmitted. Meypack or the user of the machine can use this information to recognise irregularities and thus enable early intervention in the event of servicing. Meypack utilises such functions. Jörg Peikenkamp: „We trialled the first field boxes two years ago - initially internally. In 2024, we presented the concept to our first customers and the response was very positive. Since this year, we have been using the safety field boxes as standard in all machines.“

With the AZM 300, Schmersal has developed a hygienic solenoid interlock. (Image: Schmersal)

Packaging line for packet soups

A current example of the new machine safety concept is a fully automated system for packaging packet soups. The bags are supplied to the machine via several conveyor lines, brought together on a conveyor belt and fanned out. At the same time, a carton is provided and erected. The next work station places the bags upright in the carton, which is then closed. This creates transport packaging that only needs to be opened in the retail store and serves as an eye-catching display.

Five safety field box units are installed in this system. Among other things, 20 solenoid interlocks of type AZM 300, eleven emergency stop buttons and a safety light curtain are connected. All device connections are occupied for the majority of the field boxes, which are also connected to each other.

Closing instead of just monitoring

It is not only typical for this system that all safety doors are secured by a solenoid interlock. Jörg Peikenkamp: „The reason for this is not always machine safety. Regardless of this, the user does not want the process to be interrupted because the operator opens a safety gate. Especially in systems with a high throughput, a restart can cost time or require manual clean-up work. That's why we almost always use guard locking: This increases the productivity of the systems.“

A striking feature of the Meypack systems is the transparency of the man-machine interface: the emergency stop buttons are illuminated and the switching status of the safety switching devices is easily recognisable. Jörg Peikenkamp: „The systems are becoming increasingly complex. For example, they are being supplemented with modules for checking for completeness, integrity or leaks.“ This is another reason why Meypack is simplifying and decentralising the operation and signal evaluation as well as the communication of non-safety-related functions - through the use of I/O modules, network technology and open standards such as IO-Link. As a result, the control cabinet is significantly smaller and the electrical installation is less complex. The use of Schmersal safety field boxes supports this concept at the machine safety level.