Optimising Safety in Serac's Packaging Machines

At Serac’s production hub in Klang, Malaysia, a complex challenge emerged: upgrading a legacy high‑speed filling machine to modern safety standards - without replacing its original control system. Pilz stepped in to engineer a smart, future‑ready solution for one of Asia’s most sophisticated packaging environments.

High-speed packaging machines – particularly those used in bottling lines – can operate at rates exceeding 1,000 packages per minute. To put that into perspective, the average blink takes just 300 to 400 milliseconds. In that tiny fraction of a second, the machine can already package 5 to 6 items – meaning it works faster than you can blink.  

These machines, built for precision and speed, often rely on synchronised controllers, servo motors, sensors and robotics to maintain accuracy at such speed. It’s a game-changer for end-user F&B manufacturers, but a different story for packaging innovators like Serac, who are committed to engineering machines that deliver not just speed, but also precision, reliability, and safety – creating long-term value for their customers. 

Serac’s strategic production hub for Asia, situated in Klang, Malaysia, houses some of its most advanced machinery, renowned for their compact design, hygienic operation, and high-speed efficiency. These machines serve a wide range of industries across Asia. Beyond manufacturing, Serac also retrofits older equipment with modern safety upgrades, ensuring legacy systems continue to meet today’s rigorous standards. 

Behind the scenes, the challenge isn’t just about delivering quality and performance. It’s also about navigating regulatory compliance, ensuring operator safety, and building scalability for the future – all while onboarding new staff and establishing a robust risk assessment process to support CE certification of its machinery. 

One particularly complex case involved upgrading a legacy filling machine to meet modern safety standards – without replacing its core control system. 

The machine was built around the SEW MOVI-C EtherCAT master controller (UHX45A-N/OMH45A), which did not support FSoE (FailSafe over EtherCAT) master functionality. This presented a key challenge: how could Serac introduce safety communication over EtherCAT without replacing the existing controller architecture?  

To solve this challenge, Serac turned to Pilz – a trusted name already embedded in its safety architecture. Pilz’s PNOZ safety relays and PNOZmulti 2 controllers had long been a part of Serac’s machines, valued for their reliability, flexibility, and ease of integration. Building on this established foundation, the PNOZmulti 2 system – now enhanced with the PNOZ m EF FSoE communication module – offered an innovative solution. It operated as a standard EtherCAT slave to the existing SEW MOVI-C controller, while simultaneously serving as an FSoE master on a dedicated safety network.  

• Preserve the existing EtherCAT master for motion and process control
• Introduce a parallel safety network managed by the PNOZmulti 2 system
• Seamlessly integrate FSoE-capable safety devices (e.g., light curtains, emergency stops) without modifying the main control logic

The result was a hybrid EtherCAT architecture that delivered both standard and safety communication – each on its own layer, yet fully synchronised. The machine now meets modern safety standards, while maintaining the performance and reliability of the original system.  

Pilz’s contribution extended far beyond hardware. With deep expertise in international safety standards, Pilz provided hands-on support at Serac’s Malaysian facility. Their safety specialists collaborated closely with Serac’s engineering team to review and validate risk assessments across multiple machines – both existing and in development – ensuring full alignment with CE marking and global safety regulations.  

This consultative approach not only strengthened Serac’s current safety framework but also uncovered opportunities for modular upgrades, advanced diagnostics, and ongoing optimisation. It reflected a forward-thinking safety culture rooted in continuous improvement and strategic partnership.  

Founded in France in 1969, the Serac Group specialises in the design and manufacture of liquid filling and capping machines for a wide range of industries – including dairy, edible oils and sauces, beverages, home and personal care, lubricants, paints, and food products. With decades of expertise in manufacturing on four continents, Serac excels in handling liquids and viscous products that require stringent hygiene standards, Extended Shelf-Life (ESL) and aseptic conditions, as well as precise filling accuracy.  

Serac’s solutions are engineered to accommodate various container types and demanding production environments, including configurations for explosion-proof operations. Their commitment to innovation and reliability has made them a trusted partner for manufacturers across the globe.