All Pharmaceutical Solutions



  3. Predictive maintenance enables users to more accurately anticipate when machine maintenance will be needed based on real-time data from the machines themselves.


  5. Remotely monitoring tank level can help improve efficiencies and increase productivity and profitability.

  6. IIoT technologies enable better communication throughout the factory and streamline processes for machines and people alike.











  17. To ensure that a griddle is on, non-contact T-GAGE M18T temperature sensors are aimed at the cooking surface to detect that the surface is hotter than the surrounding air. If the waffle iron is hot, the batter will be poured in and the process will continue. If it is not hot enough, the T-GAGE temperature sensor output won't trigger the batter release mechanism allowing the iron additional time to heat.

  18. To allow for quicker, more frequent, and more efficient scanning of target valve population tailpipe temperatures, a series of FlexPower Thermocouple Nodes and FlexPower Battery Supply Modules are installed. Temperature measurements of the valves and pipes are measured and wirelessly transmitted to a DXM100 Wireless Controller mounted in a central location. The DXM100 gathers the data and transfers the data to a SCADA system that monitors and graphically displays the temperature data.

  19. The SureCross Wireless Sensor Network eliminates complexities associated with data acquisition from rotating and moving machinery such as a rotating kiln. Crucial temperature data is acquired using a thermocouple or RTD and transmitted from the FlexPower Nodes to a remote Gateway in the plant's control center. Data is always concentrated in the same location for processing or analysis, and manual data collection and physical risks to personnel are eliminated. Temperature data is logged and anal

  20. Banner’s DX99 Nodes offer solutions for monitoring the temperature of motor bearings using thermocouples or RTDs. Because these are low power sensors and radios, a battery life of up to three years is possible. The Node sends temperature data wirelessly back to a central control location for logging and analysis. When the bearing temperature rises unexpectedly, maintenance can be scheduled before any motors burn out or equipment is damaged. It is likely this temperature data would not be monit

  21. Soil moisture and air temperature sensing ranges are typically under a mile, but the Site Survey tested the signal out to two miles. With the MultiHop Radio and its antenna installed very low to the ground, the Master Radio was installed with a large omnidirectional antenna to maximize the communication range.

  22. A SureCross FlexPower™ Node with internal battery directly connected to a temperature and humidity sensor can provide these measurements without costly conduit or cabling, eliminating the need to manually collect data from multiple sensor locations. IP67 electronics and a variety of filter options make this product suited for the wide temperature and humidity ranges encountered in a greenhouse.

  23. A resistance temperature detector senses the temperature of a walk-in cooler and sends the data to a SureCross FlexPower Node. The Node in turn sends that data to a Gateway, which issues an alarm to management if the temperature exceeds acceptable limits. The DX80 FlexPower Nodes have a IP67 rating for rugged environments and work well in the cold.

  24. Manual data collection is eliminated using a SureCross FlexPower™ Node equipped with two thermocouples to automatically monitor the temperature at two depths within a compost windrow or stack.

  25. SureCross devices can monitor temperature, vibration, and pressure. A mobile FlexPower Node equipped with up to three thermocouples monitors critical bearing temperature and sends the data to a Gateway for logging. With this information, maintenance personnel can service the machine based on performance indicators and minimize down time.


  27. T-GAGE M18T Series Temperature Sensors are passive, non-contacting, temperature-based devices designed to detect objects that are hotter or colder than the ambient condition, and then activate an output. In this application, the T-GAGE temperature sensor will detect the presence or absence of hot glue on the flaps of the package. If the hot glue is present, the process will continue and the package will be sealed. If it’s absent, the output will trigger a process to apply the hot glue.

  28. Banner’s T-GAGE M18T temperature sensor is ideal for hot glue verification because it detects the infrared energy an object emits to determine its temperature, sensing from 0⁰C to 300⁰C. In this application, the T-GAGE M18T temperature sensor detects the presence or absence of hot glue on the flaps. If hot glue is present, the package will continue down the manufacturing line;if it is missing, the output will trigger a pusher arm to kick the carton off the conveyor into a bin.


  30. A large cabinet maker needs to monitor and control the temperature and humidity throughout many rooms in a large production facility. Manual environmental readings of the entire plant were conducted periodically throughout the week. These manual readings only provided a snapshot of information and gathering the data took more than three hours. The customer did not have real-time, accurate information that could be used to control the plant environment. Manually collecting this information and controlling the fan system was timeconsuming and resulted in errors that damaged wood in storage, work in progress, and finished cabinets.

  31. Clinical labs need to process samples quickly to keep throughput high and any lag during testing procedures would disrupt workflow. LED lightings, such as the K50L2, works as machine status indication so that the lab operators can process fix errors, handle samples, and collect results in a timely manner.














  45. To optimize efficiency and output, the progress of multiple FOUPs in single wafer deposition machine must be closely monitored. Staff work in close proximity to these machines and prolonged exposure to bright light from tower lights can cause eye strain, leading to physical and mental fatigue. Keep reading to learn how TL30 Basic tower lights solve this application.

  46. K50 Pro touch buttons with IO-Link communication display takt time within workers' sightlines so that the assembly pace stays on track and meets production goals.

  47. Learn how the installation of Banner wireless vibration sensors and data from the DXM wireless gateway prevented unplanned downtime in this application.


  49. Detecting clear and reflective objects are some of the most challenging sensor applications. Light can burn through a target or be reflected away erratically, making accurate detection difficult.

  50. Dark objects are difficult to detect since they reflect very little light back to the sensor. In addition, black on black targets (low contrast between target and background) are especially challenging.

  51. In packaging, targets often contain vibrant, multicolored graphics of varying reflectivity. Such varied targets can be difficult to detect reliably, especially when there are many color transitions.

  52. Many applications, such as registration mark detection and high-speed part counting, require sensors with response speeds fast enough to reliably detect fast moving targets.

  53. There are many advantages of an IO-Link system including reduced wiring, increased data availability, remote monitoring, simple device replacement, and advanced diagnostics.

  54. Products with higher IP ratings are designed to work better in harsh environments where standard sensors would easily get damaged and produce false readings.

  55. Clear, thermoformed plastic containers, trays and clamshells are used to package a wide variety of products. Packagers must be able to detect the leading edge.

  56. Detect clear glass and PET plastic bottles with various shapes and sizes. Washdown environment, IP69K ratings.

  57. The Q5X laser sensor reliably detects when the staging area is clear of bottles and the system is ready for the next layer of containers, despite the transparency of the bottles and unstable signal.

  58. Sensor solutions to detect translucent bottles in a range of shapes, sizes, colors and contours in a high-speed air conveyance system, identifying gaps.

  59. Sensor solutions to verify packaging and count on conveyor. Foil and film packaging such as tea bags, multiple colors on packaging material.

  60. Sensor solutions to detect clear vials in pharmaceutical and medical manufacturing where a hygenic sensor is needed in a harsh chemical washdown environment.

  61. Sensor solutions to detect clear glass jars to be filled with food in a strict sanitary environment where frequent, high-pressure washdowns and IP69K ratings.

  62. Sensor solutions to detect bottle types with varying frequent in product changovers. High-speed labeler processing 800 bottles per minute, high temps.

  63. Sensor solutions to detect accumulations to regulate line pressure where bottles vary in size, shape, color, and translucence and there is not a reflector.

  64. Sensor solutions to detect reflective food wrappers such as Mylar with conveyor belt presence verification, utilizing foreground suppression.

  65. Using a sensor in clear object sensing mode to ensure proper staging of plastic trays during denesting process.

  66. Sensor solutions to count translucent and reflective glass vials in high-speed processes requiring quick response times and challenging light conditions.

  67. Sensor solutions to monitor a conveyor to ensure there are no stuck bottles when bottles are clear plastic in a large sensing area.

  68. Sensor solutions to count containers that are made of clear plastic when containers are various shapes and have ridges.

  69. Sensor solutions to count rings on a conveyor belt where the rings have a very reflective surface and a cylindrical shape.

  70. Sensor solutions to detect perforations on continuous web of translucent plastic bags where high-speed equipment is used and a large-volume of material process.

  71. Sensor solutions to detect glass vials filled with transparent liquid in an aseptic, stainless steel environment with rounded bottles.


  73. Sensor solutions to recognize clear glass vials and bottles in high-speed application with precise leading edge detection.

  74. Sensor solutions to detect a low contrast edges of glass on conveyor in a clean industrial environment where equipment is regularly exposed to high temperatures

  75. Sensor solutions to detect translucent bottles filled with clear liquid with a long bottling line with numerous areas to monitor.

  76. Sensor solutions to detect plastic bottles varying in color and translucence where a high-speed system requires fast response times. Accurate sorting.

  77. Sensor solutions to detect I.V. bags, glass vials, syringes and pharmaceutical packaging. Fill level inspections ensure product content amounts are accurate.

  78. Detect translucent bottles varying by size, shape, color, and faceting. Large scale system of monitoring in multiple locations, quick clearance of tipped bottle.

  79. Sensor solutions to detect small installation areas with multiple deployments on the line. Accurate detection of shiny cans supports smooth product flow.

  80. Sensor solutions to detect bottle types vary in size, shape, color, translucence, and material. Equipment is regularly exposed to harsh washdown.

  81. Sensor solutions to detect bottle types vary by size, shape, color, contours, and translucence on a rinser where equipment is regularly exposed to washdowns.

  82. Learn how the Q4X detects clear plastic trays at hopper and filling station in the food industry.

  83. Hamer, LLC is a Minnesota-based manufacturer of automated packaging equipment for a wide variety of applications and world-wide customers. From pet food to pellet fuels, Hamer machinery packages products in a variety of weights and sizes at speeds up to 60 bags per minute. A vital component of Hamer’s equipment is registration mark sensing—the ability to detect marks on packaging as it passes at high speeds. When a mark is detected, the equipment cuts the packaging at the designated location, eliminating waste and ensuring each bag is consistent.

  84. Banner’s Q3X versatile, rugged laser contrast sensor is ideal for detecting registration marks. With a range up to 300 mm, the Q3X has a tight laser spot able to detect a small white registration mark reliably. When the Q3X detects the white registration mark, the intensity readout increases and a discrete output is triggered, indicating the white registration mark is present and it is the correct package going down the line.

  85. Banner’s R58 high-speed, low-contrast expert registration sensor detects subtle registration marks on the labels as they pass at high speed—ensuring the label is cut at precisely the right moment for correct label placement. To accommodate frequent changeovers, the sensor is designed with LED color options—which automatically change depending which color best optimizes contrast.

  86. Banner’s R58 Expert registration mark high color resolution sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects splices and other defects that are otherwise hard to detect. The high sensitivity of the R58 Expert detects the inconspicuous splice in a roll of paper to ensure the printer skips over the splice during the press process.

  87. As empty tubes go down the manufacturing line, a visible light sensor can verify a toothpaste tube’s registration mark before being filled and sealed. Banner’s high-speed R58 visible light color contrast sensor is an extremely powerful sensor for registration mark applications and can easily read marks on high-gloss and low-contrast surfaces, detecting contrasts as low as two percent over a wide range of colors.

  88. Banner’s R58 Expert registration mark color contrast sensor is a high-performing sensor with an ultra fast 10 kHz switching frequency that quickly detects registration marks, which is ideal for tube positioning applications. Even with a high-gloss surface or a low-contrast situation, the R58 Expert can easily detect the registration mark on a filled tube to determine how it should be oriented.

  89. Banner Engineering’s R58B Expert registration mark sensor confirms the registration mark’s position on the web. This allows the machine to make minor infeed adjustments to ensure the cut is properly placed and all labels are consistent and complete. If the labels are incorrectly cut they need to be removed from the bottling line creating costly downtime and waste. A quick and easy-to-use sensor is needed to dramatically improve throughput.

  90. 3 Apr 2019

    A laser measurement solution enables high-speed package sorting in order fulfillment applications and helps drives failure rates down—ultimately saving costs and maximizing profits.

  91. Intuitive safety solutions from Banner Engineering make safety simple by combining easy-to-use safety devices with LED indication for fast commissioning, visual management, and remote monitoring of safety systems.

  92. Industrial safety controllers provide an interface between safety devices and the machines and processes those devices monitor for an easy-to-use safety control solution.

  93. The point of operation on a machine is where the work is performed. Because workers are in close proximity to pinch points, safety is critical.

  94. Perimeter guarding applications require guarding on multiple sides of the machine. Meanwhile, access guarding protects an access point into the hazardous area.

  95. Operators must be able to safely start (initiate) machine processes as well as safely stop them in an emergency.






























  125. Learn how magnet switches protect operators from the harmful interior of a heat sealer.


  127. An SLC4 safety light curtain safeguards a small access point on a compact machine without disrupting access or operation


  129. Pallet transfer conveyors are used to move heavy loads to the shipping area. Both the pallets and the conveyor pose risks for accident and injury and must be safeguarded. An SX5-B safety laser scanners safeguards the loading and unloading stations on the conveyor and enables a continuous flow of pallets through the system.


  131. An SC10 Series safety controller replaces the functionality of three safety relays with one compact, cost-effective device offering intuitive operation and advanced capabilities.

  132. Safe work solutions help companies overcome the challenges posed by the COVID-19 pandemic so they can more effectively serve and support their customers, employees, and communities while planning for the future.


  134. Banner’s clean workstation monitoring solution makes it easy to establish and maintain a rigorous cleaning and sanitizing schedule without disrupting productivity.

  135. Learn how to ensure health and safety of your staff by utilizing bright, high-visibility indicators and touch-free buttons in your work space.

  136. Track and trace solutions are only as reliable as the devices that scan the codes, so selecting a dependable identification technology is critical. Learn about Banner's solutions for traceability.

  137. Recalls happen, and when they do, it is critical that manufacturers respond quickly by identifying affected products and issuing a timely recall to mitigate damages.

  138. Food packaging facilities verify product barcodes at multiple points so they can quickly identify and isolate product with quality issues and ensure a safe food chain.

  139. Pharmaceutical traceability is required to eliminate counterfeits, ensure patient safety, and comply with regulations.

  140. Work in Process (WIP) tracking refers to tracking each item in production throughout the entire manufacturing process to ensure efficiency, accuracy, and traceability.

  141. Direct Part Marks (DPM) are codes that are etched or printed directly onto a part's surface. Due to poor contrast, they can be extremely challenging to read.

  142. An iVu BCR Series barcode reader with rotation range detection reads the barcode on medical product packaging and verifies that it is correctly aligned for heat sealing.


  144. Banner’s TCNM linear barcode scanner is recommended for scanning and validating the barcodes. It is able to decode over a dozen commonly used linear barcode symbols helping maintain an efficient flow of bottles along the production line. Utilizing the TCNM linear sensor allows for an automated way to confirm the correct product in real time.

  145. The iVu BCR barcode reader scans pallets as they are loaded, identifying that pallets are complete. This ensures that operators know what truck or warehouse location the completed pallet will be directed. After the iVu BCR barcode reader verifies the pallet, the pallet is taken to the warehouse for storage or loading dock for shipment. Banner Engineering’s iVu BCR barcode reader decodes a variety of barcodes, including DataMatrix, Code 128, Code 39, Codabar and many more.

  146. Banner’s TCNM linear barcode scanner quickly and easily detects up to 10 linear barcodes on packages, helping maintain accountability and an efficient flow of packages throughout a distribution center. The TCNM linear barcode scanner is ready to scan right out of the box with SMART TEACH, providing scan rates of 500 to 1,000 scans per second. The linear barcode scanner can read barcodes in ranges from 40 to 600 mm.

  147. Banner’s iVu Plus BCR Gen 2 with remote display offers an easy to use solution for reading barcodes to ensure correct labels have been applied. The iVu Plus BCR Gen 2 models provide both a fine mode, for reading smaller barcodes that require full resolution, and coarse mode, for applications where speed is critical.

  148. Medicine bottle labels include both a linear and a 2-dimensional barcode. The PresencePLUS P4 BCR reads both types simultaneously to verify that they are correct.

  149. The PresencePLUS P4 BCR industrial barcode scanner reads and verifies the small 2D bar code affixed to a component of a cell phone.

  150. The Pro, equipped wtih a barcode reader tool, enhances compliance with federal requirements for identifying and tracking pharmaceutical products.

  151. An iVu BCR with UV ring light is an ideal solution for detecting barcodes in a low contrast situation. The iVu is coupled with UV illumination for an all-in-one solution that improves contrast on clear labels so bar codes are easily detected.

  152. A PresencePLUS P4 BCR industrial barcode reader detects and verifies the subtle 2D barcode that was stamped into a metal gear so it can be tracked through production and in the field.

  153. The iVu BCR is used in many mail applications to help direct mailers from multiple smaller runs as they are combined into larger ones.



  156. A part is tracked using both a linear and a 2-dimensional barcode. The high-resolution PresencePLUS P4 BCR 1.3 reads both types simultaneously to verify that they are correct.



  159. Barcode position can change with the location of each box on a conveyor and the height of the boxes can vary. An ABR 7000 barcode reader decodes multiple 1D and 2D barcodes over a large area in a single inspection, regardless of position or orientation.

  160. Barcodes used to track packaged produce through the supply chain contain important product information that must be verified at multiple points during packaging. An ABR 3000 barcode reader ensures that the barcode on each package is present and correct.

  161. Direct part mark (DPM) codes can be small, complex, and difficult to distinguish from the material they are etched into. The ABR 7000 barcode reader is available in models specifically designed to solve challenging low-contrast and DPM applications like this.

  162. It is critical that 2D codes on pharmaceutical bottles are properly verified for product recalls and other quality assurance measures.

  163. On electronic assembly lines, reliably identifying and reading small 2D Direct Part Marking (DPM) codes is essential. These information-dense codes track data at the component level, such as serial number and date of production.

  164. Pick-to-light devices from Banner Engineering create a versatile, scalable solution to improve the efficiency and accuracy of a wide variety of picking applications. We help you identify a light-guided picking solution to match your application requirements, from small assembly stations to large order fulfillment racks.

  165. Pick-to-light systems support lean manufacturing initiatives by reducing the risk of human error in production and assembly processes.

  166. Put-to-light solutions improve the efficiency and accuracy of stocking and replenishment activities and can help prevent downtime by reducing delays due to misplaced or incorrect parts.

  167. Light-guided kitting and sequencing solutions allow operators to focus on building high-quality products while maintaining efficiency.

  168. Quick, accurate picking increases customer satisfaction by ensuring that customers receive the correct order in a timely manner.



  171. Banner’s K50 Optical Pick-to-Light series is a compact, self-contained, three color indicator with integral sensor. Green typically indicates which part to pick, and when the internal sensor detects the hand, the indicator changes to yellow to confirm the task is complete. An optional third message is to display red for a mispick.

  172. The system controller issues an instruction to pick an item from a particular location. The controller turns on the PVA’s job lights at the specified location. The job lights go off when an item from that location is removed. If multiple items are required from one location, the job light stays on until the correct number of items are removed. The bright light of the EZ-LIGHT PVA pick-to-light sensor makes it possible to see which part to pick from a distance, saving time.

  173. A pair of EZ-LIGHT PVA pick-to-light sensors are mounted to a rack on either side of a bin. In response to a signal from a process controller, the PVA illuminates to show the assembler which part to pick next. When the assembler's hand enters and leaves the bin, the controller recognizes that the part is picked and lights up the PVA for the next bin in the pick sequence.

  174. The PVL provides 100% reliability over a large area and can be mounted directly to the racking profile. The PVL can also be mounted in a vertical or horizontal orientation to suite application needs. This versatility allows for a quick set up and quick and efficient processes.

  175. Several technologies and solutions are available for bin-picking applications for error-proofing processes. Light arrays prompt the operator for part selection with integral job lights, then reliably sense retrieval of the part, using an array of visible red or infrared sensing beams located in front of the bin.




  179. Each wide shelf is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor in retroreflective mode, which has a range of up to 2 m. The PVD lights up on the bin from which the worker should select the map to ship.


  181. In a book packing warehouse, the rack above each carton of books is equipped with a one-piece EZ-LIGHT PVD pick-to-light sensor. A worker fills orders by selecting the quantity of each book specified on the packing slip. To make it easier for the worker to find the cartons from which to pick books, the PVDs above those cartons are illuminated. The PVD detects the workers hand in the carton to verify that the title was picked.





  186. Manual kit building at large stations can be time-consuming and subject to human error, especially if storage racks are difficult to navigate. The PTL110 series pick-to-lights are scalable for large systems and highly versatile to complete numerous tasks.





  191. Push-button EZ-LIGHT K50 pick-to-light sensors on a rack of parts light up to indicate which parts to pick. After picking a part, the worker pushes the button on the indicator light to verify that the pick is complete.

  192. Learn how a golf equipment manufacturer recently used PTL110 pick-to-light devices to simplify and accelerate their final product assembly and order fulfillment processes.

  193. Read more to learn how the Pick-to-Light Solutions Kit improved pick sequences and ensured a high level of quality assurance at mutiproduct assembly workstations.

  194. We provide rugged illumination for the harshest environments. Our high performance LED lights are low maintenance throughout their 50,000 hour or more lifespan, for years of trouble-free operation.

  195. Well-lit machines are easier to monitor, troubleshoot, and maintain. Heavy duty LED lights are built-to-last in harsh environments and provide years of bright illumination.

  196. Proper lighting reduces the risk of errors during assembly and inspection tasks, saving time and costs. Good lighting also improves worker ergonomics and reduces eye strain.

  197. Compact LED lighting can help reduce errors and speed up maintenance tasks in confined spaces like equipment cabinets and other enclosures.

  198. Visual inspection of parts and components helps manufacturers identify issues early to minimize wasted time and costs. In these applications, the right lighting is a must.

  199. An EZ-STATUS device includes both white and colored LEDs. The device can perform both task lighting and status indication functions with a single unit.


  201. Banner’s WLS28 Work Light Strips provide numerous energy-efficient solutions for illuminating work areas and enclosure interiors with intense, long-lasting and durable cool white light. These LED lighting strips not only provide even, extremely bright cabinet illumination, but they also conveniently fit in the enclosure and can be plugged into any local power source.


  203. Illumination during photolithography processes is challenging because white light contains a percentage of blue wavelengths, which negatively affect photosensitive materials. The WLS15 strip lights switch between two colors for safe use during photolithography.

  204. Placing WLS27 Multicolor LED Strip Lights with EZ-STATUS above PCB assembly machines provides area lighting and status indication with one rugged and versatile light. Any changes in machine status cause the WLS27 to switch from illumination to indication and cover the entire machine with the corresponding color. This type of indication allows operators to focus on the task at hand without missing changes in machine status.

  205. Machine lighting inside of automated clinical labs helps operators see and access the samples and equipment being used inside. These types of environments can be difficult on traditional lights because of the reagents and chemicals used during testing and cleaning. The WLS28-2 is rated IP69K to withstand chemicals and washdowns.



  208. Accidents can happen when people and mobile equipment share intersections in a factory. See how to create a controlled intersection with multicolor lights.

  209. Lighting inside of paper drying machines is helpful during maintenance and general operation of the paper production line, but illumination is difficult because of the high heat in the machine and the wet environment. The WLH60 high temperature LED light can withstand heats as high as 100° C and is rated IP67, IP68G, and IP69K for water, oil, and chemical resistance.

  210. Learn how green LED task lights enhance visibility of surface imperfections on manufacturing materials.

  211. Automotive inspection requires consistent, bright light with minimal glare to inspect automotive parts. Increased lighting can improve worker productivity and reduce eye strain.

  212. Liquid-dosage pharmaceutical product packaging inspections involve minute human visual inspections, making it important to have bright and highly uniform illumination.

  213. High visibility is critical during inspection of product in flexographic printing because the lighting assists in monitoring machine performance. The HLS27 LED Strip Light works well near flexography printing machines because they are designed to work safely in Division 2 hazardous locations. The bright light illuminates printing functions to assist visual inspection.

  214. Banner’s WLB32 Industrial Light Bar is ideal for workstations. With a Hi/Lo/Off switch, operators are able to control the lighting level and are able to switch the LED light bar off when they are done. The WLB32 provides workers high brightness with even light output and enables numerous tasks in a workstation, including working on a computer.

  215. Banner’s WLS28 Work Light Strips with ON/OFF switches provide an energy-efficient solution for illuminating work areas and enclosure interiors with intense, long-lasting light. These LED lighting strips provide even, extremely bright illumination, and can easily fit in limited space setups. The work lights can be plugged into any local power source for simple operation.

  216. The energy-efficient WLB92 is easy to install and accommodates a wide variety of application needs with several models available. The light is extremely bright; effectively illuminating a robotic cell area. AC conduit models provide easy installation throughout the cell. The high-quality WLB92 LED light was designed to have an aesthetically-pleasing look, yet be rugged enough for industrial environments.

  217. WLS27 LED strip lights provide brilliant, even illumination in difficult environments like this. Each light is protected against environmental challenges and corrosion by a shatterproof, water-resistant polycarbonate shell. A redundant sealing method prevents water ingress to achieve IEC IP66, IP67, and IP69K ratings. These cost-effective LED light strips will provide vivid, low-power, maintenance-free illumination throughout their 50,000 hour or more lifespan.


  219. The heavy-duty, energy-saving WLB92 from Banner Engineering provides an extremely bright lighting solution that provides consistent lighting across a warehouse. Since the LED factory light is so bright and gives a uniform output, fewer lights are needed in total, helping reduce the overall cost of lights and installation time.




  223. Banner’s WLB72 Inspection is a very bright LED luminaire that features an even light output for a no glare glow. This LED light bar uses advanced LED technology to provide a high-quality and maintenance free industrial lighting solution. The unique lensing provides a dark-to-light-to-dark transition on a vehicle surface suitable for detailed inspection tasks.

  224. The WLS27 Pro with IO-Link is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in indication, illumination, and inspection applications. Learn how the WLS27 Pro with IO-Link provided operators the necessary information and illumination to decrease product changeover times and maximize productivity.

  225. The WLS27 Pro with discrete control and configured by Banner’s Pro Editor software is one of two new models of the WLS27 Pro series strip light. It now includes programmable RGBW LEDs for use in illumination, indication and inspection applications. Learn how the configurable WS27 Pro provided forklift guidance for warehouse operators.

  226. With its low-profile and sleek design, the LC15T is an easy-to-use interface for controlling a wide range of DC devices. The LC15T effectively communicates status to users with green, blue, and red colors to indicate different device states.

  227. Learn how the WLS70 strip light provides bright, even illumination inside robotic weld cells.

  228. Machine status indicators improve communication across the manufacturing floor. By enabling immediate attention to problems, machine status indicators reduce downtime and help increase productivity.

  229. Local indication solutions provide clear, highly visible status alerts to both operators and plant managers in their normal sightlines.

  230. Combine bright, colorful LED indicators with wireless technology to remotely monitor your operations for real-time insights in any location and faster troubleshooting.

  231. LED indicators with advanced programming capabilities can display dynamic statuses like fill level, takt time, machine transitional states, and more.

  232. An EZ-STATUS device includes both white and color LEDs. The device can perform both task lighting and status indication functions with a single unit.

  233. In automotive manufacturing, maximizing efficiency is crucial in order to meet production goals. Delays at assembly stations can hold up processes later down the line, leading to costly wasted time and missed production targets. The TL50 Pro tower light helps assemblers meet expected cycle times and support overall takt time requirements.

  234. TL50 Pro tower lights clearly informs operators that maintenance procedures are in progress with advanced action mode animation.

  235. Indicator lights intuitively direct traffic through truck wash stations to ensure efficient flow of vehicles through the wash. However, high-pressure washdowns, cleaning agents, and outdoor environments make status indication challenging. Learn why the WLS27 segmented strip lights are a better alternative to traditional stoplights and can help improve efficiency at truck wash stations.

  236. The S15L Series In-Line Sensor Status Indicator is a two color indicator light that indicates power and output status. Its inline connection, over-molded design and bright indication create a cost-effective solution that can be applied to most 4- or 5-pin devices with an output.

  237. Learn how a retail store used TL50 Pro tower lights with USB to visually tell customers which automated checkouts were available for use, which were down for cleaning, and which were being used while they were waiting in long lines.

  238. Smart laser measurement sensors from Banner Engineering reliably solve the most challenging measurement and inspection applications, even in real-world environments.

  239. Level measurement solutions assess fill levels and provide accurate, real-time data from a wide variety of containers or tanks.

  240. Extremely tight tolerance requirements demand a reliable solution that measures parts in micrometers to detect small variations in part size, thickness, orientation, placement, and more.

  241. Maintaining the correct level of tension on web materials ensures quality and reduces unplanned downtime. Measuring roll diameter is fundamental to maintaining appropriate web tension.

  242. Reliable web and edge guiding ensures a continuous flow of product through machine processes, minimizes downtime and prevents material damage and loss.

  243. The K50U wireless ultrasonic sensor was designed specifically as a non-contact level monitoring solution. Monitoring the levels of epoxy in drums during refill alerts staff of potential overflows before they become a problem.

  244. Banner’s U-GAGE QT50U ultrasonic analog long distance sensor has a narrow sensing beam that works in confined areas, such as the tank, without interference from the tank walls and senses with an extended range up to 8 m. The ultrasonic sensor can be mounted to the center so that the beam spreads over the tank to detect the fluid level without interference, while signaling when to pump out excess liquid and pump in additional liquid.

  245. Banner combined the technology of WORLD-BEAM QS30 opposed mode sensors, which provide high excess gain, with a 1450 nm infrared sensing beam—specially tuned to an absorption band of water, to create the QS30H2O Water Sensor. In this application, the powerful sensing beam of the QS30H2O will burn through the opaque plastic of the container. At 1450 nm, water absorbs 1,000 times the energy of alternative wavelengths, preventing the beam from burning through the liquid within the container.

  246. Elevators, escalators and moving sidewalks are major investments in any facility’s infrastructure. This equipment is expected to operate safely and reliably for many years and with minimal downtime for maintenance. To meet these expectations, a large-scale manufacturer of vertical and conveyor transport equipment performs rigorous tests on all system components. The data that is collected helps the company estimate component life expectancy and plan service schedules.

  247. The Q4X analog sensor is set up in trigger mode and uses the averaging feature to provide a more consistent fill level measurement. Banner’s Q3X sensor, whose output wire is tied to the Q4X’s remote input wire, is used to detect the leading edge of the pill bottle and has a one-shot output timer setup based on the conveyor speed to determine when and how long the Q4X will measure.



  250. Banner’s U-Gage QT50U ultrasonic sensor excels at the most challenging level applications, bouncing sound off any solid surface—even those that may vary in consistency or contrast. The sensor is available with a Teflon-coated transducer cover, making it resistant to harsh chemicals and suitable for the food and beverage industry. Ultrasonic sensors are able to provide accurate monitoring of pump-controlled tanks by sending a continuous signal to measure the current tank depth.

  251. Banner’s SureCross wireless system can easily transmit temperature, pressure and fill levels to a local PLCs. The wireless system will seamlessly alert operators if bottling is occurring below the desired fill level. This helps prevent errors and leads to greater consistency in bottled beverages. Consistent fill levels mean no recalls—and no wasted products. Using a wireless system also eliminates the need for slip rings on the rotary filler, which in turn reduces maintenance costs.

  252. Using a wireless level monitoring system, day tank fill levels are now monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference. With a SureCross Wireless Network, FlexPower™ Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a T30UF ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. Remotely located tank sensor readings can be forwarded to a host system for data tracking, sending e-mail alerts, or to trigger specific events, such as refilling the tank. Tank resources are only filled when necessary to maintain customer-defined levels. Time is no longer wasted performing routine refills on tanks that did not need to be refilled.


  254. The two-point teach option on the Q4X analog laser measurement sensor is used to teach the full and empty magazine. Manual adjustment can be used to fine tune the output. The analog output provides a real time gauge of the stack height. This allows the cartoner machine to have several “call for parts” set points without having to manually move the sensor. The Q4X is a robust, rugged stainless steel sensor ideal for use in many industrial, factory environments.

  255. Alternative data collection solutions are possible with Banner’s DX99 900 MHz radios in CID1 housings and the B/W Prostick magnetostrictive level devices. Using the appropriate antenna barrier, the result is a Class 1 Division 1 wireless monitoring solution that provides real-time data anywhere within the facility. With the battery powered DX99 units and the loop powered Prostick, installation into the 8' flanged tanks takes only a few minutes.

  256. The two point teach option on the analog setting can be used teach the front of the flat cases as the 20 mA point and can easily be adjusted for a manual set of the 4 mA to the end of the cases. This helps gauge how many flat cases are left, so more cases can be added when the case count is getting low. The digital output can also be used for presence detection. This helps ensure there is a case available to be picked up, and also ensures only one box is picked up at a time.

  257. A brew pub uses EZ-LIGHT indicator lights as a remote display of the status of the levels in the brew tanks. The indicators are connected to ultrasonic sensors within the tanks that cannot be monitored easily.

  258. Automatically monitoring the tank levels and controlling the pumps out in the gas field eliminates human error and can more quickly prevent costly spills. When the battery of salt water tanks is filled, a signal is sent wirelessly from the tank battery to the field pump to shut down the well. When the tank battery and pump are separated by miles of terrain, Banner’s MultiHop radios are an ideal solution.

  259. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

  260. The dough for one of the company’s many popular breakfast cereals must fall within specific height parameters to ensure that it will have the perfect flake. Dough that is too thick will emerge from baking stiff and heavy. Dough that is too thin will crumble easily. This impacts the quality, taste and texture of the final product as well as product weight and packaging. Any product that does not meet the rigorous quality standards of the company will not be shipped or sold on the consumer market.

  261. Banner’s SureCross DX99 wireless FlexPower Nodes offer Class I, II, and III, Division 1 and Zone 0 certifications for installations requiring Intrinsically Safe operation. With a SureCross Wireless Network, FlexPower Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a pressure sensor to operate for years on a single DX81 battery power supply.

  262. To wirelessly monitor and report level, pressure, and temperatures in the rotary fillers, each rotary filler was equipped with a FlexPower Node and DX81P6 6-pack battery supply. The FlexPower Node had two 0–20 mA analog inputs and one thermistor input while the battery pack supplied power to the Node and sensors for more than a year. A level probe, pressure transmitter, and thermistor (not supplied by Banner) were connected to the FlexPower Nodes and installed in the rotary tanks.

  263. An L-GAGE LT3 laser distance-gauging sensor, mounted above the hopper, measures the distance to the material's irregular surface, enabling a PLC to calculate the bin’s fill level.

  264. Banner's tower lighting solutions, such as an EZ-LIGHT TL50 Tower Light, can be mounted on top of the pump panel to easily communicate the status of the pump. The highly visible light tower allows employees to quickly check the panel, without needing to open the panel door. Multiple lights can be on simultaneously, so several messages can be conveyed at once, and the audible alert provides indication that the pump is overheating and immediate attention is required.

  265. Sensors connected to a wireless network monitor the fluid level in storage tanks. Because only 120V ac power is available at the tanks, the SureCross wireless network converts the available line power. The weather-resistant SureCross devices are protected against the elements, preventing time-consuming maintenance.


  267. In this application, an EZ-ARRAY measuring light screen is being used to measure the length of the log. The EZ-ARRAY determines the total number of beams that are blocked by the log and communicates the length of the log to an operator station by sending the information to the system controller in the form of a MODBUS RTU-485 output. The operator station controller then provides a number of options to the operator, who selects which cuts are made.

  268. SureCross Nodes with FlexPower and Banner U-GAGE QT50U analog sensors quickly and easily facilitate these monitoring requirements without new construction and wiring. The FlexPower Node transmits the sensor data back to the Gateway device. When using a Gateway Pro, data is logged and alerts can be sent when fluid levels reach critical levels.


  270. The DF-G3 fiber optic amplifier, used with plastic fibers, is a precise solution for edge guiding during lithium-ion battery assembly. Proper edge guiding reduces the amount of wasted product.

  271. Banner’s expertise in sensing, vision, pick-to-light, and industrial illumination technologies allows us to offer optimal solutions to detect defects, measure components, monitor tolerances, verify product attributes, and reduce the possibility of mistakes or errors--all while increasing productivity.

  272. Automated quality control ensures consistent, reliable inspection of parts and components and helps manufacturers identify potential issues early on in the manufacturing process.

  273. Identifying the cause of errors and mistakes and correcting those conditions is fundamental to error proofing (poka yoke) and promotes a Lean manufacturing environment.


  275. Pick-to-light systems support lean manufacturing initiatives and improve quality by reducing the risk of human error in production and assembly processes.

  276. Dark packaging with multiple colors transitions can be difficult to detect with traditional red LED sensors. Banner Engineering’s miniature VS8 photoelectric sensor with blue LED works well with low reflectivity labels to detect refrigerated food packaged in pressurized cans. The small sensors fit into tight spaces and work well for short range applications. The blue LED works with the small spot size to minimize the effects of color transitions on the labels.

  277. Banner Engineering’s miniature VS8 sensor fits atop a glue gun to accurately detect the presence of adhesive as it is being applied. The VS8 is taught the distance between glue gun and PCB and can detect the very small height distance after the adhesive gets applied and recognize if there are any gaps or bubbles. The miniature sensors fit into tight spaces common in electronics assembly.

  278. In large distribution facilities, sortation trays deliver products to the proper bin for correct shipment. Before sorting can begin, each tray needs to be empty so that items can be placed on the conveyor and sent to the next location. The 5mp VE Smart Camera recognizes very fine levels of detail and can detect items of almost any size, confirming the presence or absence of items on the trays.

  279. Banner Engineering's Q12 miniature self-contained sensor detects pucks that hold vials as they move through an automated clinical laboratory. Poor performing sensors could inadvertently cause errors and slow down the throughput of the lab. The Q12 is a good fit for clinical laboratories because it is small and can fit into confined spaces without affecting results. The fixed field sensor can also detect pucks regardless of color.

  280. • Confirm presence and orientation of IC chips • Sensor performs multiple functions at once • Cost savings and versatility

  281. The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

  282. Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.



  285. Banner’s Q4X laser sensor, made of 316L grade stainless steel, is very suitable for pharmaceutical environments and other aseptic filling areas. The Q4X has a sensing range of 25 to 300 mm, precise beam spot size and can effectively detect the orientation of caps as they exit a feeder bowl. If any caps are upside down, the Q4X will detect a height difference and reject the cap.



  288. To solve this application, Banner Engineering has paired the technology of the D10D Expert with fiber optic arrays optimized for small object counting to create the D10 Expert Small Object Counter. The preconfigured fiber optic arrays of the Small Object Counter make alignment and object positioning control less critical than when using single point emitter and receiver fiber optic assemblies. This assures reliable, consistent small object counting.


  290. Banner's DF-G1 Series amplifier provides a simple setup and calibration for small part counting applications. Once the amplifier is setup, the easy-to-read digital dual display allows for simple operation because it shows the signal level and threshold simultaneously.



  293. The solution uses an iVu Series sensor configured for a Match inspection. A reference "good" identifier is taught into the sensor. In service on the production line, the sensor detects when a component does not have the correct identifier, and sends a fail output to the line, and the part is rejected.


  295. The DF-GI amplifier, with the fiber optic sensing tip positioned near where the robot applies the adhesive, verifies that adhesive is applied to the IC chips. Opposed pairs of VS2 sensors detect when the level of filled wafer trays exceeds a preset height.


  297. A WORLD-BEAM QS18LD diffuse-mode laser sensor can be used to accurately inspect each package as it passes on a conveyor. The sensor emits a visible Class 1 laser sensing beam, focused on the piece of tape used to seal the package. When the top of the box is closed and sealed correctly, the tape will return the sensing beam back to the receiver.



  300. Banner’s R55F fiber optic sensors have the capability to detect the presence of caps regardless of their color or size – a clear advantage in an industry that has a wide variety of bottle caps and frequent line changes. In this type of application, the fiber optic sensors are used to recognize long pauses between the caps which would then signal a jam to the operators of the machine. The fibers are compact and can be easily mounted in confined and typically inaccessible spaces.


  302. When a production operator needs supplies, the operator toggles the switch connected to the Wireless Q45. The corresponding K50 EZ-LIGHT light on the display board lights up, signaling to forklift drivers where they are needed.

  303. Alert operators of the fail status on a checkweigh station on a food processing line in a harsh washdown environment.

  304. The customer was looking for a single-output solution that senses packages quickly, is easy to install and maintain, and was affordable enough to buy in bulk quantities if needed.

  305. • Precise location detection • High-speed conveyor • Customer specific product

  306. Learn how the Q4X detects dark colored trays at hopper and filling station in the food industry.

  307. The QS18LD laser diffuse sensor scans across the top of the package to see if any flaps are open. The laser diffuse sensor provides accurate detection to verify whether the frozen packages are sealed properly.

  308. Banner’s rugged PresencePLUS P4 Sealed OMNI vision sensor works well for date/lot codes because it uses Optical Character Verification/OCV inspection to ensure the correct day and lot code are printed legibly. With an IP68-rated housing, the sensor is ideal in food and beverage applications because it can withstand harsh wash-down environments. The P4 OMNI sensor easily locates the region of the carton magazine that needs to be inspected for date/lot codes by verifying the edge of the box. Wi

  309. A precise measurement solution is required to ensure that integrated circuit (IC) chips are present and oriented correctly in nests. Learn how the LM laser measurement sensor solves this application.

  310. The unique indication of the programmable K50 Pro touch buttons and Pro Editor software allows for versatile indication of numerous machine statuses and in-field customization. Multicolor and animation allow for quick identification of errors in work cells.




  314. To verify each blister in the pack, use an iVu Series sensor configured for an Area inspection. The sensor inspects each blister pack to make sure that each blister contains an unbroken tablet.


  316. A single VE Series Smart Camera, adjacent to the machine’s outfeed, inspects multiple rows of blister pack trays in a single inspection. The camera is installed approximately 36 cm over the production line and an LED backlight is installed 10 cm below the production line.

  317. The Banner Q3X laser diffuse sensor is ideal for applications that require orientation detection with small contrast differences.

  318. The Q3X is Banner’s rugged, versatile laser contrast sensor, ideal for applications that require fast detection. As parts go down the conveyor, the Q3X will be able to detect if the o-ring is present based on the taught contrast differences. If the o-ring is not present, the Q3X will see a bright signal level and send an output to the PLC. This alerts operators to fix the error or move the part off of the production line.



  321. One global provider of healthcare products had been using vision machines to detect particulates in their liquid pharmaceuticals. When the machines were no longer able to detect contaminants to the required percentage level, the company began using human visual inspections. Since many of the particulates are extremely minute, the company needed to install bright and highly uniform illumination in their work stations so operators could effectively verify the quality of products.

  322. A VE Series Smart Camera inspects the product logo on each box before the tube of toothpaste is inserted. As a box enters the inspection area, it is detected by a sensor on the line and an output is sent to the trigger input on the camera, which captures an image of the region of interest (ROI). A red LED ring light powered by the camera enhances the contrast between the product logo and the surrounding packaging.

  323. To verify each package has a date/lot code printed on it, an iVu Series sensor is configured for a Match inspection. An image of the date/lot code is captured. When the inspection is running, if the sensor detects a package without the date/lot code the sensor sends a fail output to the line, and the product is rejected.

  324. To verify each box is correct, an iVu Series sensor is configured for a Match inspection with 360 degree rotation enabled. An image of the correct box is captured and when the inspection is running, if the sensor detects an incorrect box, the sensor sends a fail output to the line, and the product is rejected.


  326. To confirm that each unit includes a product information insert, an iVu Series sensor is mounted above the packaging line. The sensor is configured for a Match inspection, and checks that the product information leaflet is inserted into each package of medication. The leaflet can be placed in any orientation, but must beface up.The sensor can detect 360 degrees of rotation to find the insert.

  327. To ensure that a stopper is properly inserted as each vial leaves the filling station, an iVu Series sensor—set up for an Area with Motion application—verifies that the vial has a stopper inserted into its neck and that the stopper is positioned correctly to provide a proper seal on the glass vial. If the stopper is missing or incorrectly positioned, then the sensor sends a fail output to the line.

  328. A sealed PresencePLUS Pro COLOR vision sensor is encased in an enclosure that protects it from damage in a wet environment. The Pro checks for label presence and placement.


  330. To verify each product, an iVu Series sensor is configured for a Match inspection. An image of a good product package is captured. When the inspection is running, if the sensor detects a package with a different or missing label, the sensor sends a fail output to the line, and the product is rejected.

  331. By pairing Banner’s DF-G2 with four opposed mode PLIS-1 fiber optics, operators can ensure that a wafer is placed correctly on the end effecter of a robotic arm, ensuring that no damage is done when passing it into the chamber.



  334. Banner Engineering’s iVu vision sensor inspects presence vent tubes and spreader washers on a busy bottling line. It uses a 50 mm C-Mount lens to extend the working range of the sensor to avoid contact with spray and liquids.

  335. To verify each integrated circuit, this application uses an iVu Series sensor configured for an Area with Motion application. If the sensor detects a part with missing or damaged solder balls, or if it detects any foreign material, the sensor sends a fail output to the line, and the part is rejected.

  336. An iVu BCR sensor is mounted 8-12 inches above a conveyor of boxed pill bottles containing a medical information insert. The iVu BCR industrial bar code scanner reads a data matrix code on the insert to verify it matches the product on the packaging line. When a box containing an incorrect insert or no insert at all moves past the iVu BCR inspection area, the iVu detects this fail condition and sends an output alarm to the production line.

  337. iVu Series vision sensors are ideal for monitoring materials to ensure that specific quality standards are met. It provides users with complete control and immediate feedback for setup and monitoring of products. It features multiple sensor types, including a blemish sensor, which is the best mode for this application.

  338. The solution uses a PresencePLUS P4 OMNI, a Standard 16 mm lens, and an On-Axis Diffused LED light. A Geometric Count tool that was used to build the inspection searches the entire image for the pattern of a good vial. The pattern consists of edge outlines of the inside and outside diameters (ID and OD) of the vial opening. A mask is used to remove the reflection from the inside bottom of the vial.

  339. Banner iVu TG vision sensor with multi-point inspections is ideal for detecting and evaluating the position of tamper-evident bands. In this application, the band should be positioned around both the cap and the neck of a bottle. A seal positioned too high, too low, or completely missing would be considered unacceptable. With multi-point inspection, the iVu TG vision sensor can simultaneously detect missing and poorly positioned bands.

  340. In this illustration, precision machined bolts have just come out of the feeder bowl and are moving down the feeder bowl rail, conveying to the next automated step. As they move down the rail, a WORLD-BEAM QS18 detects the bolt and sends a triggering signal to an inspection sensor, the iVu Image Sensor. The iVu is configured to detect a flaw in the flange, irregular shape of the bolt head, or other flaws that might be present.



  343. It is critical to verify the position of the stoppers since improperly sealed or positioned stoppering can compromise the product's integrity. Vision inspection offers a flexible, powerful, and effective method to inspect for seal quality and stopper position for the vial filling process. For stoppers with full insertion, we are looking for the minimal amount of gap between the bottom of a stopper relative to the top of a vial.

  344. An iVu TG Image Sensor works well for label verification because it comes with four sensor types, including a match sensor. The match sensor determines whether a pattern on a label matches a reference pattern and if it is correctly oriented. With just the touch of a button—or remotely through a PLC—users can easily teach the iVu image sensor to recognize and match the correct label pattern, requiring no image processing expertise.

  345. Because disk surfaces are shiny, many sensors have difficulty detecting whether a hard disk is properly seated in a hard drive. Banner Engineering’s Q3X and Q4X sensors are designed to detect shiny surfaces with a wide variety of colors, textures, and materials.


  347. The P4 OMNI vision camera is located immediately after the bottles leave the labeler which assures that the presentation of the label will be in a repeatable manner and therefore can be compared to a stored image for a match. The P4 OMNI is sealed to IP68 and made with nickel plated zinc housing.

  348. A PresencePLUS Pro COLOR vision sensor verifies that pour spouts inserted into detergent bottles are present, fully inserted, and the same color as the bottle. The IP68 sealed housing protects the sensor and ring light from liquids.


  350. By detecting differences in surface height, the precise laser beam of the extremely compact self-contained L-GAGE LG Series short-distance laser sensor can detect breaks in the bead of glue that a robotic glue gun applied to a panel.

  351. A PresencePLUS P4 COLOR OMNI vision sensor verifies that a case is fully packed with bottles with matching bottle caps. The sensor detects whether any bottles are missing from the case, whether any bottles are uncapped, and whether any caps are the wrong color.

  352. In the application shown, the plastic wrap surrounding the cap and the top of the can serves several purposes: it acts as a tamper-proof seal on the can, it prevents the cap from disconnecting during transit, and it holds the applicator tool to the can. Additionally, the plastic serves as error-proofing to protect customers from spilling the contents before they are ready to use it. For these reasons it is important that cans without the plastic wrap are rejected.


  354. This application uses an iVu Series sensor configured for a Match inspection. It ensures that the music label is face up and within a small rotational tolerance. If the sensor detects a CD that is incorrectly oriented, it sends a failure to the line, and the CD is rejected.

  355. Tightened federal regulations make the quality of pharmaceutical packaging increasingly critical. A PresencePLUS Pro COLOR vision sensor inspects blister packs to make sure each blister contains the correct tablet and that the tablet is not broken. It also detects empty blisters and those containing foreign matter.


  357. To rapidly verify that beer bottles are filled to the correct level and that caps are correctly aligned, a high-speed PresencePLUS P4 vision sensor locates the bottle and verifies the fill level and cap placement. This helps eliminate the need for multiple sensors, while accurately detecting the presence of caps and monitoring fill level. The red backlight provides a strong contrast to the bottles, amplifying the bottle features for easy detection.

  358. A high-resolution PresencePLUS P4 OMNI 1.3 mounted above a conveyor inspects each box of 12 chocolate candies, making sure each paper nest contains one candy and that the candy is intact.

  359. As plastic bottles pass below the WORLD-BEAM Q12 Sensor, the fixed-field beam identifies bottles with caps—no matter what their color—and rejects bottles that are missing caps from the line. The Q12’s laser-like LED beam sharply cutoffs at 15 mm, 30 mm and 50 mm range, ensuring it won’t mistake objects inside the bottle for caps.

  360. The rugged PW12-rated World-Beam Q12 sensor inspects bottle closures using fixed-field technology to ignore cap color changes. With many types of bottles and product coming down the line, it is important for the sensor to ignore the size of the cap whether it is 25 or 50 mm. Using the same fixed-field technology, the Q12 easily ignores color and size changes in caps, while detecting whether or not a cap is present.

  361. To verify an electronic component like that shown, an image of a good part was captured using an iVu Series sensor configured for a Match inspection. If the sensor detects a part with a bent or missing connector, or if the part is wrong side up, the sensor sends a fail output to the line, and the part is rejected.

  362. After bottles are filled and capped, they are conveyed under the WORLD-BEAM Q12 sensor at close range, before they are packed in cartons. The Q12 sensor, operating in fixed-field mode, detects missing or misaligned caps—regardless of color—and triggers the line to reject uncapped bottles. Because the sensor uses fixed-field mode, it responds when a cap is not at the exact distance from the sensor that it should be.

  363. A PresencePLUS OMNI inspects the neck of a clear plastic bottle to verify that the date/lot code has been imprinted on the bottle. It also confirms that the cap is properly applied and that the bottle's fill level is within the acceptable range.


  365. In an application with limited space, the WORLD-BEAM Q20 sensor is easily positioned to verify the presence of a label before it is applied to the product.

  366. The solution involves using an iVu Series sensor configured for a Match inspection. The sensor evaluates each plastic bottle and, if the bottle is not well formed, the sensor sends a fail output to the line where the plastic bottle is rejected.

  367. An SLM series slot sensor and an iVu Series vision sensorare used to detect bottles passing on the line and to verify that date/lot codes have been correctly printed onto the bottles.

  368. After a technician places vials in a tray based on each vial's color-coded lid, a PresencePLUS P4 COLOR OMNI verifies that the pattern of colored vial lids is correct.


  370. A PresencePLUS P4 COLOR OMNI mounted about a conveyor inspects each box of 12 chocolates, making sure each paper nest contains the correct type of candy, based on color. It rejects boxes that have the wrong chocolate in a nest, are missing product or have damaged product.

  371. A PresencePLUS P4 COLOR OMNI vision sensor inspects pour spouts that have been inserted into detergent bottles. The sensors verify that the spout is present and inserted fully, and that spout color matches the bottle color. A special bracket positions the area light at an angle that maximizes contrast and color visibility.

  372. As each salad dressing bottle leaves the label station, an iVu Series vision sensor, configured to use the Match tool, inspects the label, comparing it to a preconfigured reference image to ensure that the label is present and has been correctly applied.

  373. As glass bottles pass on a high-speed conveyor, a PresencePLUS P4 COLOR OMNI confirms that each bottle is completely filled and makes sure that the stopper is fully inserted and is the correct color. The dual area lights create the optimum contrast for the inspection.

  374. A successful manufacturer of specialty industrial yarns makes fiberglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimize costly product returns, they established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.

  375. Banner sensors are positioned above a conveyor inspecting each passing box for missing chocolates. When a passing box breaks the trigger beam created by a pair of Q12 opposed-mode sensors, an array of QS18AF sensors mounted above the box inspect each location for missing chocolates. When a box containing the wrong amount of chocolates is detected, an output signal is relayed to a main controller at the packaging line warning of the failed condition.

  376. To ensure that product quality standards are met and that product appearance is consistent with the brand, the company must inspect each bottle to ensure that the right bottle cap is present and properly seated.

  377. An iVu Color Sensor identifies RGB values of individual pieces of trim on vehicle door panels and communicates this information over an industrial Ethernet connection to a PLC.

  378. The Q5X verifies the presence of dark components on a dark background--as well as vehicle seats and components of varying colors.

  379. The Q5X sensor verifies the presence and position of reflective targets in a harsh environment.

  380. How anti-glare color sensors reliably verify tablet presence and color through reflective blister packs.

  381. Banner Engineering provides many wired and wireless solutions for vehicle detection, and we partner with you to help match the right technology to your application..

  382. A drive thru vehicle detection solution can alert employees to a customer’s presence at a window, count the number of cars passing through, monitor time spent in the drive thru, and more.

  383. Vehicle detection solutions for parking applications can reliably verify when a garage is full, activate a pay station, direct drivers to available parking spots, and more.

  384. Vehicle sensing technologies verify that vehicles are correctly positioned in the car wash bay, monitor the flow of traffic, and trigger next steps like opening and closing doors.

  385. Vehicle detection at a loading dock can be used to identify available bays, facilitate fast load and unload times, verify vehicles are in the correct position before opening doors, and more.



  388. A large retail shopping center reduced vehicle congestion, customer aggravation and drive-offs using wireless sensors.

  389. Sensor solutions to add vehicle detection to Fire Department dispatch and reporting systems.

  390. Sensor solution to identify correct cars are parked at charging stations, alert officers.