For several years, one of the greatest challenges in packaging lines has been getting the different machines to work in perfect synchrony. Each equipment (from the bagging machine to the wrapping machine) had its own control system, communication protocol and interface, which resulted in costly integrations, slow diagnostics and lines that were less flexible when faced with format or product changes.
The PACKML (Packaging Machine Language) standard was created precisely to solve this issue, establishing a common communication protocol that allows all machines on a single production line to communicate with each other and function as a coordinated system. In this article, we will discuss this standard in greater detail.
What is PACKML and how does it improve integration?
PACKML (Packaging Machine Language) is a standard created by OMAC (The Organization for Machine Automation and Control) and adopted by ISA como TR88.00.02. Its aim is to harmonise data exchange between machines from different manufacturers on a production line.
In practical terms, PACKML defines a set of principles that make this integration feasible:
- Common operating states: all machines follow the same operating sequences (standby, starting, running, stopping, etc.), thus simplifying control and diagnostics.
- Unified interface: HMI screens display consistent structures and messages, enhancing the operator experience.
- Standardised data: information is exchanged using uniform tags (PackTags), simplifying connection to upstream systems (MES, ERP or SCADA).
- Reduced integration time: by sharing a common language, line commissioning is faster, more predictable and less costly.
According to OMAC, PACKML enables faster commissioning, greater operational consistency and a significant reduction in average maintenance downtime.
How it works: states and operating modes.
PACKML is based on the standardisation of states and operating modes that enable uniform control between equipment.
Machine states.
hese represent the different phases of the operating cycle (stopped, starting, running, maintaining, suspended, completed, etc.). Thanks to this structure, monitoring systems can understand where each machine is in the cycle and react to incidences in a consistent way.
Some of the most relevant states are:
- • Stopped
- • Starting
- • Idle
- Execute
- Stopping
- Aborting
- Aborted
- Holding
- Held
- Suspending
- Suspended
- Resetting
- Completing
- Complete
Operating modes.
These define the general type of operation (automatic, manual, or maintenance), which facilitates coordination between operators and systems.
The combination of states and modes provides a logical structure that improves interoperability, operator training, and operational efficiency.
Figure 1: The PackML Interface State Model. Source: OMAC.
How is PACKML applied in a packaging line?
Thanks to PACKML, equipment manufacturers can easily design equipment that seamlessly integrates with each other.
For example:
- Bagging, palletising, and wrapping systems share information without the need for complex programming.
- New machines can be integrated without redesigning the entire control architecture.
- Maintenance technicians identify malfunctions and alarms in a uniform manner, reducing downtime.
- Connection to upstream systems (MES, ERP, SCADA) is simplified thanks to standardised data structures.
What are the benefits for companies?
PACKML provides measurable benefits in plant management and operation:
- Operational efficiency: all machines ‘speak the same language,’ reducing downtime and coordination errors.
- Flexibility: lines can be adapted to new formats or products more quickly.
- Cost savings: less engineering time and lower integration complexity.
- Uniformity of use: consistent interfaces that simplify operator training.
- Greater traceability: standardised data that allows for more accurate performance analysis.
The OPC Foundation highlights that adopting PACKML improves the ability of plants to integrate into Industry 4.0 environments, where interoperability and communication between systems are essential.
Although PACKML has greatly improved the way machines connect, there are still challenges to overcome in order to expand its outreach and impact, most notably:
- Not all companies are familiar with it or apply it.
- Older machines may need to be adapted for use.
- The standard must continue to evolve to include new technologies such as the industrial internet and artificial intelligence.
Comparison between standard line and line with PACKML.
| Aspect | Standard line | Line with PACKML |
| Integration between equipment | Each machine with its own system, complex integration | Common language, simple integration |
| Maintenance and diagnostics | Non-standardised events and alarms | Faster and more uniform diagnostics |
| Flexibility | Difficult to add new equipment | Easy incorporation of new machines |
| Engineering costs | High due to customised developments | Cost reduction through standardisation |
| User experience | Different interfaces for each machine | Similar and more intuitive screens |
TMI’s commitment to PACKML standardisation.
At TMI, we are progressively integrating the PACKML standard into all our solutions: from automatic bagging systems to palletising and end-of-line equipment.
This process requires a thorough review of control architectures, HMI interfaces and data structures, as well as close collaboration between the engineering, software and technical service departments.
Adopting PACKML is a strategic decision that reinforces the quality of our solutions, facilitates their integration with third-party systems and prepares our equipment for the challenges of the connected industry. Each step forward on this path brings us closer to more efficient, flexible and sustainable production lines.
Would you like more information about our solutions? Contact us here.
Oriol Miarnau
Lead Automation Engineer
