Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

Ocean Spray rides a new bus

On a new Craisins line at Ocean Spray, point-to-point wiring between machine devices and their master PLC has been replaced on some machines by an open fieldbus called AS-i. Installation time is slashed, while in-plant flexibility is maximized.

In this automated bag-inserting machine, nearly 60 devices communicate with their master PLC via a fieldbus instead of through t
In this automated bag-inserting machine, nearly 60 devices communicate with their master PLC via a fieldbus instead of through t

The programmable logic controllers that operate so many packaging machines today are only as good as their ability to receive input signals and respond with outputs. Until recently these signals were typically carried on dedicated, point-to-point wiring. But now another alternative is available, and for the engineers at Ocean Spray Cranberry’s Tomah, WI, plant, it has meant shorter installation time and undreamed-of flexibility in adding or relocating I/O devices. Most important, it means PLCs from a wide variety of makers can be seamlessly integrated along the same communications line, or bus.

Called AS-Interface, or actuator-sensor-interface, this new communications network is most commonly called AS-i. Whatever name it goes by, it’s an open, vendor-neutral fieldbus supported by many established manufacturers. It connects photoeyes, proximity switches, push-buttons, valves, relays and any other sensing or actuating device on a packaging machine with that machine’s PLC. It replaces traditional point-to-point hard wiring between each of a machine’s slave devices and the master PLC they serve. And it does this, says the AS-i Trade Organization (Scottsdale, AZ), with no sacrifice in speed of data transmission. According to AS-i, in a configuration with 31 separate devices, the scan cycle time is 5 milliseconds. With 62 different devices, scan cycle time is 10 milliseconds.

At the Tomah plant of Middleton, MA-based Ocean Spray, AS-i is the device-to-PLC communications link on two of the five machines in a new packaging line. Commissioned last May, the line packs dried and sweetened cranberries, or Craisins®, into 10- and 25-lb boxes for food processors who use Craisins as an ingredient. The line consists of a case erector, bag-in-case inserter, combination scale/filler, bag uncuffer/flap-closer and case taper. Ocean Spray’s Dave Frenz, senior process engineer, was influential in bringing AS-i to the Tomah plant.

Also enthusiastic about specifying AS-i as the fieldbus in its individual machines was Pearson Packaging Systems (Spokane, WA). “When I told each machine vendor that I’d need an AS-i block in each of their machines to handle machine-to-machine communications, the Pearson people said they wanted their bag inserter and bag uncuffer to also rely on AS-i as the slave device-to-PLC communications link,” says Frenz. “They’re going in that direction anyway, and they saw this as a great application opportunity.”

The simplicity of the AS-i bus is among the things that impresses Frenz the most.

“Take a look at a packaging machine control panel with an AS-i bus line compared to one without,” says Frenz. “The AS-i version is so much cleaner. There are no big wire trains, just one two-wire cable that wraps around the whole machine.”

Masters and slaves

The two-wire cable Frenz refers to is what connects sensors and actuators with their master PLC. This electrical connection is made using contacts that pierce the cable’s insulation, thus contacting the two wires inside. This eliminates any need to strip the cable and wire it to screw terminals. That saves time during initial installation and when replacing worn components. As Frenz puts it, “You just clamp on anywhere along the cable that you want.”

Frenz views this nearly instant connectivity as a huge benefit.

“If you want a photoeye somewhere, or an air valve or some other actuator, you just clamp it right on. You don’t have any wires to run back to the PLC, so you don’t have to call the electrician.”

Also, says Frenz, the cable material is what he describes as “self-sealing.” “I can unclamp and move a device any time I want without having to somehow reseal the cable,” he says.

Break out of the ordinary: see what’s new in packaging & processing!
At PACK EXPO Las Vegas, you’ll see machinery in action and new tech from 2,300 suppliers, collaborate with experts and explore transformative solutions. Join us this September to experience a breakthrough in packaging and processing.
REGISTER NOW AND SAVE
Break out of the ordinary: see what’s new in packaging & processing!
Annual Outlook Report: Sustainability
The road ahead for CPGs in 2025 and beyond—<i>Packaging World</i> editors review key findings from a survey of 88 brand owners, CPG, and FMCG readers.
Download Now
Annual Outlook Report: Sustainability