Software-Defined Automation and Open Digital Integration in Secondary Packaging

As part of SEW-EURODRIVE's strategic journey toward an industrial automation paradigm increasingly defined by software, a new application developed in synergy with Sidel and TTTech Industrial demonstrates how energy efficiency, high-performance motion control, and open digitalization can converge in the secondary packaging segment. The EvoFilm^® Stretch solution, engineered by Sidel for the cold secondary packaging of PET bottles, cans, and glass, eliminates the need for traditional heat-shrink tunnels by utilizing stretch film (LLDPE). This approach cuts plastic material usage in half for a savings of up to 50%, reduces production plant energy consumption by up to 90%, and guarantees an extremely compact machinery layout—ideal for facilities focused on maximum efficiency and sustainability.

The UBIQUE Digital Ecosystem and the Cultural Shift in Software
The distinctive value of EvoFilm^® Stretch lies in overcoming traditional infrastructure constraints by integrating the UBIQUE platform, developed in collaboration with TTTech Industrial. This paradigm shift is based on complete hardware independence: the platform is designed to be entirely agnostic to physical devices, allowing the control software to run on different architectures without being tied to a specific vendor. By leveraging the EtherCAT CiA 402 communication standard, the system coordinates distributed hardware flexibly and centrally, safeguarding industrial investments over time.

Innovation also extends to engineering accessibility through the use of advanced tools and high-level programming languages such as Python. This methodological choice turns the machinery into an ideal environment to attract and empower young digital talent, who can operate with modern and familiar tools, thereby accelerating innovation cycles. In the field of operational data protection, the architecture adopts native cybersecurity criteria (secure by design), ensuring default protection against cyber threats in full compliance with the strictest international industrial security standards.

"For Sidel, EvoFilm^® Stretch represents an important evolution in secondary packaging. The growing interest from our customers and the orders received motivate us to continue developing this technology, thereby contributing to a more sustainable future for the sector." — Carlo Gioria, Director of Product Management – EoL & Tunnel at Sidel.




Mechatronic Infrastructure and Modular Energy Management
The dynamic management and millimeter precision of the film unwinding, pack wrapping, and bundle handling phases are entrusted to a high-performance technological combination from SEW-EURODRIVE. The core of the automation is governed by the MOVI-C^® modular system, an integrated platform that oversees all drives, ensuring maximum flexibility with minimal energy expenditure. The software platform runs on board the powerful IPC UHX86A industrial PC, consolidating the new paradigms of software-defined automation.

The control cabinet layout has been optimized to reduce the overall footprint in the plant through a modular automation philosophy. The adoption of compact MOVIDRIVE^® modular systems allows two motors to be managed by a single dual-axis driver, rationalizing physical space. Meanwhile, the movement of the transport systems is delegated to MOVIGEAR^® performance drive units in CiA 402 mode, which, thanks to their IE5 efficiency class, guarantee the highest level of energy eco-efficiency. The precision dynamics are backed by CM3P... series synchronous servomotors coupled with BS.F low-backlash servoreducers.

Within the application, ten drives operate in perfect synchronism through dedicated software modules that simplify the configuration of even the most complex kinematic trajectories. Line safety is entirely centralized via the SCU (Safety Controller) unit, while the human-machine interface is digitalized through the SEW-EURODRIVE WOP web panel. From the initial concept phase to on-site commissioning, SEW-EURODRIVE’s engineering expertise ensures continuous operational flows and a fluid transfer of multipacks to subsequent processes in the logistics chain.

Edited by Maria Brueva, Induportals editor – adapted by AI.

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