Breakthrough in Blister Packaging: Elos Medtech Revolutionizes their Machinery with XTS
- Jeff Johnson
- Sep 25
- 4 min read
Intelligent transport system increases flexibility in dental component packaging
Elos Medtech aimed to standardize automation throughout their machines for dental component production and packaging. After expanding their XTS linear transport system, the company was able to easily add new machine modules for cartoning blisters.
With global headquarters in Sweden, Elos Medtech, part of Elos Group, is one of Europe’s largest manufacturers of orthopaedic and dental implants. Their factory in Gørløse, Denmark, specializes in the development and manufacturing of dental components.
In 2018, Elos Medtech was the first company in Denmark to develop a new packaging machine based on the XTS from Beckhoff. Leveraging the flexibility of the modular transport system with the individually controllable movers, Elos Medtech was able to automate the previously manual packaging of dental components into blister packs.
In day-to-day operations, the fast changeover capabilities of XTS helped increase productivity and reduce resource consumption. The setup for Elos Medtech’s packaging machine only takes 10 to 30 minutes. "We need to run many different, small-volume batches every day, so the machine’s flexibility and quick changeover capabilities are crucial for us,” says Rune Callesen, head of the automation department at Elos Medtech. "This packaging machine is fully validated against the strict requirements applicable in the medical industry for a clean, dust-free environment, high precision, reliability, quality control, and testing for complete traceability."
Simple machine expansions with XTS
As a machine builder, Elos Medtech’s goal is to standardize the automation of its machines across the board. According to Callesen, "We are very far along in standardizing our automation, especially compared to larger machine automation vendors, where this is an extensive and lengthy process. With the 'Elos Medtech Modulized Automation Standard,' we have created a uniform platform that encompasses hardware, software, and networking.”
This allows Elos Medtech to easily move modules, add hardware, and standardize cable or network connections and software interfaces. “With this packaging machine, we fully applied our standard, which benefited us when we added extra modules,” Callesen adds.
With the new modules, the machine will be able to package components not only in loose blisters but also blisters with outer packaging and printed labels. This development requires an additional paper cutter in the machine, a magazine module for the carton blanks, and a new printer module.
Elos Medtech has also added two vision modules that check the items being packaged as well as the placement and content of the labels. Previously, the machine contained two robots installed in the machine bed. After the expansion, the robots are mounted on rails on the ceiling of the machine cell and can move freely back and forth to free up space and handle more tasks.
Maximum flexibility and integration
Callesen says that the future-proofed design of the technologies on which the 2018 machine is based inspires great confidence. “Everything is modular, reusable, open, and easy to use,” he explains. This allowed Elos Medtech to simply add machine modules instead of building a whole new machine, ensuring both sustainability and investment protection.
"The open platform from Beckhoff supports our way of thinking. We can tie everything together and even integrate third-party hardware seamlessly. In doing so, we don't have to work with multiple types of automation software. That’s a big advantage for us.” says Callesen. Elos Medtech has separate suppliers for both their vision cameras and their robots’ servo equipment. Beckhoff’s open PC-based control allowed them to seamlessly integrate automation technology even with technology from other suppliers.
Callesen also appreciates that third-party software can also run on the industrial PC without additional effort. One example is the printer, which uses specific software, yet can be installed directly. The alternative would have been to develop a complicated solution for sending print commands via the network or to use a separate PC for printer control. The network architecture is also easy to work with because the EtherCAT Coupler from Beckhoff with Fast Hot Connect ports takes care of identifying the modules in the network topology if they are moved. This technology makes it easy to quickly create the correct configuration for all connected components, according to Callesen.
"The technologies just work – for us there is no real alternative to Beckhoff. In my opinion, the solutions from other suppliers don't integrate as well," says Callesen. "The support is also top-notch. We have two programmers in the Danish branch and have to ensure 24-hour operation. Beckhoff always steps in quickly when needed and is also happy to share expertise and even Gray code that we can adapt ourselves. We see working with Beckhoff as a true partnership, and the many benefits for us as a company reinforce our decision to choose Beckhoff as a supplier."
Elos Medtech’s partnership with Beckhoff has enabled them to transform their packaging operations into a flexible, scalable, and future-proofed solution. By leveraging the modularity of XTS and the openness of Beckhoff’s PC-based control, the company has achieved faster changeovers, seamless integration of third-party technologies, and the ability to expand without costly redesigns. Now, Elos Medtech can continue to innovate with confidence, knowing that they are ready to adapt with each new step this industry takes.
Ready to transform your own packaging machine designs with intelligent transport tech? Connect with your local Beckhoff sales engineer to get moving today.
Jeff Johnson is the Mechatronics Product Manager at Beckhoff Automation LLC
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