Pneumatic Solutions for the Packaging Industry

Why Packaging Operations Demand Precision Fluid Power Control

Packaging machinery combines high cycle rates, mixed contamination, frequent operator interventions, and aggressive OEE targets in a single operating envelope. Five operating realities determine valve selection on a packaging line.

High-cycle duty across multi-axis pneumatic systems.

A typical case-packing cell may include 12 to 30 pneumatic actuators driven through a single manifold, cycling 30 to 60 times per minute. A single station can execute well over 10 million cycles per year. Sliding-seal designs degrade predictably under this duty, producing the slow internal leakage that increases cycle time and air consumption before any visible failure.

Frequent operator access for jam clearance, changeover, and product switchover.

Packaging lines stop and restart far more often than upstream process equipment. Each operator entry is a regulated event under OSHA 29 CFR 1910.147 and ANSI/ASSE Z244.1-2024. The pneumatic energy isolation device must dump downstream pressure quickly, lock in the off position, and provide visible verification that energy is dissipated. Slow exhaust paths and ambiguous lockout indicators add seconds to every intervention and minutes to every changeover.

Mixed contamination from product, environment, and ambient air.

Vacuum packaging pulls film aerosol and ink mist through the vacuum circuit. Thermoforming generates plastic particulate. Molded pulp aspirates fiber and water vapor. Blow molding handles colorant and resin dust. End-of-line case packing operates downstream of dusty cardboard handling. Spool clearances are vulnerable to silting in any of these conditions. Poppet valves with self-cleaning seal geometry tolerate the same load without performance loss.

Vacuum-circuit open-center exposure on standard 3/2 valves.

The two-station 2-way DALE Poppet Series CP manifold eliminates the open-center exposure entirely. A brief open-center condition during valve shifting exposes the vacuum pump to atmosphere. On valves ported above one inch, this may collapse pump vacuum, wastes energy, and stretches cycle time by several hundred milliseconds. The ROSS DALE Poppet series is a proven solution for this issue.

Audit-ready compliance under ANSI/PMMI B155.1-2023.

PMMI's C-Type standard for packaging and processing machinery requires that energy isolation devices be lockable only in the off position, that they provide a full-size exhaust port with capacity equal to or greater than the supply port, and that they include a visible pressure indicator. Most vented ball valves used as a low-cost lockout device do not meet these requirements. Purpose-engineered energy isolation valves like the ROSS L-O-X 15 Series do.

These five realities determine what a packaging-line valve must do. The remainder of this page explains how ROSS valve architecture answers each one.

ROSS Controls Product Solutions for Packaging

The following ROSS product series are matched to the discrete control functions of a packaging line. Each entry explains the product's role on packaging equipment and links to the published series page on rosscontrols.com.

• Dale Series CP and LF: Standard-Pressure Base-Mounted Poppet Valves

  The Dale Series CP and LF are base-mounted poppet valves engineered for standard-pressure packaging applications. The two-station 2-way CP configuration is the ROSS solution for vacuum packaging open-center elimination, and CP and LF manifolds are the high-Cv directional control choice for thermoforming and blow molding mold actuation.

• Dale Series CX and LX: Leak-Tight Vacuum and Low-Pressure Poppet Valves

  The Dale Series CX and LX are the leak-tight, low-pressure, vacuum-rated members of the Dale family. Bubble-tight poppet shutoff makes them the correct selection for vacuum hold during seal cycles, leak-test circuits inline with packaging, and low-pressure assist-air control where pressure decay would corrupt the process.

• Dale Series CP and CX Manifolds: Multi-Station Packaging Manifolds

  The Dale CP and CX manifold platform consolidates multiple Dale valves on a shared body, eliminating intermediate piping and dead volume between the valve and the actuator. Manifold mounting tightens cycle time on vacuum, thermoform, and blow-mold applications and reduces fitting count and leak-point exposure across the machine.

• DM2C Series Safe-Exhaust Double Valve: Category 4 PLe Pneumatic Energy Isolation

  The DM2C Series is a redundant, internally monitored safe-exhaust double valve certified to ISO 13849-1:2023 Category 4, Performance Level e (PLe), and SIL 3. It blocks supply and rapidly exhausts downstream pneumatic energy when the safety circuit commands a stop. Dynamic monitoring of the dual valve elements detects asynchronous shifting on every cycle, dynamic memory prevents self-reset after a fault, and integral diagnostic feedback meets the diminished-performance monitoring requirements of ANSI/PMMI B155.1-2023.

• DM2C Safe-Exhaust Valve, Explosion Proof: Hazardous-Location Packaging

  The explosion-proof variant of the DM2C delivers the same Category 4 PLe safe-exhaust function in a housing rated for hazardous-location packaging environments such as solvent-based aerosol filling, flammable-liquid filling, and certain food and pharmaceutical processing zones with regulated atmospheres.

• L-O-X 15 Series Lockout and Exhaust Valve: OSHA- and PMMI-Compliant Energy Isolation

  The L-O-X 15 Series is a manually operated three-position lockout valve that blocks supply, exhausts downstream pneumatic pressure through a full-size exhaust port, and accepts up to four padlocks in the lockout position. It dumps one cubic foot of 100 psi compressed air in 1.2 seconds (versus over four minutes for many vented ball valves), is lockable only in the off position, and includes a visible pressure indicator. The L-O-X 15 Series complies with the energy-isolation device requirements of OSHA 29 CFR 1910.147 and ANSI/PMMI B155.1-2023, where many vented ball valves do not.

• L-O-X with EEZ-ON Soft Start, 15 Series: Lockout with Controlled Re-Energization

  The L-O-X with EEZ-ON Soft Start combines the L-O-X energy isolation function with a soft-start valve that gradually re-pressurizes the downstream system on release. This eliminates the actuator slam and pressure spike that occur when a fully exhausted system is re-energized at full plant pressure, and it is the recommended configuration for packaging machines with large air volumes downstream of the lockout.

• EEZ-ON 27 Series Soft-Start Valve: Controlled Machine Startup

  The 27 Series Soft Start EEZ-ON is a stand-alone soft-start valve for controlled pressurization of packaging-machine pneumatic circuits at startup. It prevents cylinder runout, tooling slam, and ejected workpieces during the air-on transient and is rated to Safety Category 1, PLc under ISO 13849-1.

• W65 Series ISO 5599-2 Spool-and-Sleeve Valves: Plug-In Manifold Automation

  The W65 Series provides ISO 5599-2 standard spool-and-sleeve valves with plug-in connections, the appropriate selection for OEM packaging machine builders requiring interchangeable, industry-standard manifold connections. The W65 supports 4/2 and 5/2 functions and mounts directly to multi-station manifold sub-bases on case packers, palletizers, and filling-line automation.

• W66 Series ISO 15407-1 and ISO 15407-2 Spool-and-Sleeve Valves: High-Density Manifolds

  The W66 Series provides compact ISO 15407-1 (drop-cord connection) and ISO 15407-2 (plug-in connection) spool-and-sleeve valves for high-density manifold assemblies on modern packaging cells. The W66 platform is the standard selection for multi-axis case-packing, palletizing, and end-effector control where station count and panel space drive the design.

• PACK Series Multi-Station Valve Manifolds: Pre-Assembled Multi-Axis Control

  The PACK Series provides pre-assembled multi-station valve manifolds with two through twelve or more stations for multi-actuator packaging cells. PACK manifolds reduce installation time, plumbing complexity, and leak-point count on cells that otherwise would require individually piped valves at each station.

• Serial Bus with TURCK Modular I/O: Industry 4.0 Connectivity

  The ROSS Serial Bus product integrates ROSS ISO valve manifolds with TURCK modular I/O for fieldbus connectivity (DeviceNet, Profibus, EtherNet/IP, and other protocols). A 12-station packaging-cell manifold connects to the line PLC over a single fieldbus cable, replacing dozens of individual wire runs and supporting the diagnostic visibility and remote configuration that Industry 4.0 packaging operations require.

• MD3 and MD4 Series FRLs: Air Preparation for Packaging Equipment

  The MD3 and MD4 Series Filters, Regulators, and Lubricators provide point-of-use air preparation for packaging machines and zones. The MD3 covers 1/4 inch through 1/2 inch ports with flow to 110 scfm. The MD4 covers 3/8 inch through 3/4 inch ports with flow to 205 scfm. Filtration removes the particulate and moisture that degrade valve performance, precision regulators hold supply pressure within specification across cycle-to-cycle demand variation, and lubrication extends valve and cylinder service life on high-cycle packaging duty.

ROSS/FLEX: Custom Solutions for Packaging Applications

Standard ROSS products fit most packaging applications, but every line has at least a few machines with non-standard manifold configurations, retrofit constraints from a previous-generation OEM platform, integrated function requirements a catalog product does not match exactly, or competitor-replacement adapter needs that justify a custom approach. The ROSS/FLEX program addresses these applications by repackaging the same proven internal valve components used in standard ROSS products into a custom external configuration built to the machine's specific requirements.

The ROSS/FLEX engineering team develops custom valve assemblies in days or a few weeks rather than months. Because the internal components are already qualified through ROSS production testing, the custom assembly inherits the life-cycle and performance data of the standard product, with no new component qualification or extended sample-and-test cycle required. ROSS/FLEX solutions are available in both poppet and spool-and-sleeve configurations and are compatible with any incumbent valve brand on the line.

Four ROSS/FLEX configurations are common in packaging.

• The first is custom multi-station vacuum manifolds for high-rate vacuum packaging cells, where the standard CP or CX manifold needs additional station count, mixed flow ratings per station, or non-standard porting to fit the cell's pneumatic backbone.
• The second is integrated valve assemblies that combine multiple functions (form vacuum, knockoff air, assist plug, and seal-clamp control) on a single body for a thermoforming station, reducing field connections and tightening dead volume.
• The third is competitor-replacement adapter plates that allow a ROSS valve or manifold to drop into the footprint of an underperforming or end-of-life valve from another manufacturer, eliminating the need to re-pipe the machine when upgrading.
• The fourth is custom L-O-X energy isolation packages with integrated soft-start, pressure indication, and full-flow exhaust sized to the specific packaging machine's downstream volume, delivering ANSI/PMMI B155.1-2023-compliant energy isolation in a single drop-in assembly.

ROSS/FLEX program benefits for packaging

• Custom configurations delivered in days or a few weeks, not months
• Proven internal components inherit standard product life-cycle and certification data
• No new component qualification or extended sample testing
• Competitor-replacement adapters protect existing piping and panel layouts
• Integrated function combinations reduce field connections and leak-point count

Frequently Asked Questions

• Q: What safety standards apply to packaging machinery pneumatics?

  Answer:

  The governing C-Type safety standard for packaging and processing machinery in North America is ANSI/PMMI B155.1-2023, published by PMMI (The Association for Packaging and Processing Technologies). It guides suppliers and end users through a formal risk assessment and defines requirements for safeguarding, energy isolation, and safety-related control systems. OSHA 29 CFR 1910.147 is the U.S. federal Control of Hazardous Energy (lockout/tagout) regulation that applies to all packaging operations. ANSI/ASSE Z244.1-2024 covers lockout, tagout, and alternative methods including single-point lockout. ISO 13849-1:2023 defines performance levels for safety-related parts of control systems. ANSI B11.0-2023 provides the underlying risk-assessment methodology. ROSS products are third-party certified to meet or exceed these requirements.

• Q: What does ANSI/PMMI B155.1-2023 require of a pneumatic energy isolation valve?

  Answer:

  ANSI/PMMI B155.1-2023 requires that safety shut-off and exhaust valves be lockable only in the off position, that they include a full-size exhaust port with capacity equal to or greater than the supply port, and that they include a visible pressure indicator so personnel can confirm energy is dissipated before access. Most vented ball valves used as a low-cost lockout device do not satisfy all three requirements. The ROSS L-O-X 15 Series is purpose-engineered to comply with all three: it is lockable only in the off position, accepts padlocks and hasps, exhausts through a full-flow port that dumps one cubic foot of 100 psi air in 1.2 seconds, and includes a visible pressure indicator that confirms downstream energy dissipation before any personnel access.

• Q: What is the difference between traditional lockout/tagout and alternative single-point lockout for packaging?

  Answer:

  Traditional lockout/tagout (LOTO) under OSHA 29 CFR 1910.147 requires complete de-energization of all energy sources and physical locking before any maintenance access. Alternative lockout under ANSI/ASSE Z244.1-2024 permits the use of control-reliable safety components and a single-point lockout (SPLO) device to isolate hazardous energy faster for routine, repetitive production tasks such as jam clearing, infeed adjustment, and product changeover. On a packaging line, an SPLO configuration typically combines a safety PLC for the electrical safety circuit with a ROSS DM2C Series safe-exhaust double valve for pneumatic energy isolation. Documented packaging-line implementations show lockout time reductions of multiple minutes per incident, which over a shift can return the equivalent of an entire additional production run while maintaining the highest level of safety integrity.

• Q: Why is the two-station 2-way Dale CP manifold preferred for vacuum packaging over a single 3/2 valve?

  Answer:

  When a single 3/2 poppet valve is used to apply and vent vacuum on a packaging cavity, the brief open-center transient during shift exposes the vacuum pump to atmosphere through the valve. On systems with valves ported above one inch, this transient collapses pump vacuum momentarily, wastes pump energy, and stretches cycle time on the next stroke. The two-station 2-way Dale CP manifold uses two independent 2/2 valves arranged so that one is always closed when the other is open, and the manifold geometry never connects the vacuum port to atmosphere through the pump. The result is preserved pump vacuum, tighter cycle time, and lower energy per cycle. The Dale Series additionally provides Cv up to 100 per valve, bi-directional flow, and a 20-million-cycle rated life, which match the duty profile of high-rate vacuum packaging cells.

• Q: What certifications do ROSS DM2C safe-exhaust valves carry for packaging applications?

  Answer:

  ROSS DM2C Series safe-exhaust double valves are third-party certified to ISO 13849-1:2023 Category 4, Performance Level e (PLe), and SIL 3, which are the highest functional safety ratings available for pneumatic safety valves. They carry DGUV (formerly BG) certification, CE marking, CSA/UL certification, and EAC declarations. SISTEMA libraries are published for download to support safety system performance-level calculations under ISO 13849-1:2023. The DM2C uses redundant internal valve elements with crossflow paths and dynamic monitoring that detects asynchronous valve element movement on every cycle, with dynamic memory that prevents the valve from self-resetting after a fault is detected. The DM2C Explosion Proof variant is available for hazardous-location packaging applications such as solvent-based aerosol filling and certain regulated-atmosphere processing zones.

• Q: Which ROSS valves are best for high-density manifold automation on case packers and palletizers?

  Answer:

  The ROSS W66 Series ISO 15407-1 and ISO 15407-2 spool-and-sleeve valves are the standard selection for high-density manifold automation on modern packaging cells. The W66 platform is engineered for compact station spacing and supports both drop-cord (15407-1) and plug-in (15407-2) connection styles. The W65 Series ISO 5599-2 valves cover the full-size ISO 5599-2 footprint where flow capacity and standardized interchangeability matter more than minimum station spacing. Both platforms accept the ROSS Serial Bus integration with TURCK modular I/O, allowing a 12-station case-packer or palletizer manifold to connect to the line PLC over a single fieldbus cable. The PACK Series provides pre-assembled multi-station manifolds for applications where a packaged, ready-to-install manifold reduces installation time and field plumbing.

• Q: Can ROSS create custom pneumatic valve solutions for unique packaging machine requirements?

  Answer:

  Yes. The ROSS/FLEX program enables custom engineering by repackaging proven internal poppet and spool-and-sleeve components into custom external configurations: combining multiple valve functions into a single body, creating adapter plates to replace underperforming valves from other manufacturers, building complete air distribution systems for a specific packaging cell, and configuring custom port locations and flow ratings. Because ROSS/FLEX uses internal components already qualified through standard product testing, life-cycle re-testing is not required, and delivery is measured in days or a few weeks rather than months. ROSS/FLEX solutions are compatible with any incumbent valve brand on the line, so the program can be used both for new packaging machine designs and for in-service line upgrades and competitor replacements.

• Q: How do ROSS solutions help packaging operations reduce energy and air consumption?

  Answer:

  ROSS poppet valves eliminate the open-center vacuum waste common in standard 3/2 valve installations through the two-station 2-way Dale CP manifold approach, preserving pump vacuum across cycles. The L-O-X 15 Series exhausts one cubic foot of 100 psi air in 1.2 seconds versus several minutes for many vented ball valves. Dale Series valves deliver Cv up to 100 with bi-directional flow, allowing supply circuits to be sized for actual demand rather than oversized to compensate for valve restriction. MD3 and MD4 FRLs hold supply pressure within specification, preventing the over-pressurization that drives air consumption without improving cycle time. Combined with reduced downtime from SPLO implementations, the total operating cost impact on a high-cycle packaging line is substantial.