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In today’s packaging environments, one of the ongoing challenges is getting different machines on a production line to work together seamlessly. From bagging to wrapping and palletising, each piece of equipment has traditionally operated using its own control system, communication protocol and interface. This often leads to complex integrations, slower fault diagnosis, and reduced flexibility when changing products or formats.

PACKML (Packaging Machine Language) was developed to address exactly this challenge. By introducing a standardised communication framework, PACKML enables machines from different manufacturers to operate as a unified system.

In industries such as food and beverage processing, packaging automation and manufacturing, standardised communication between machines is essential for efficient production.

What is PACKML?

PACKML is a globally recognised standard developed by OMAC (Organisation for Machine Automation and Control) and aligned with ISA TR88.00.02. Its purpose is to standardise how machines communicate and operate within a production line.

In practical terms, PACKML introduces:

• Common operating states
  All machines follow the same operational states (such as starting, running, stopping), making it easier to monitor and control the line.
• Standardised interfaces
  Operator screens (HMIs) present information in a consistent way, improving usability and reducing training time.
• Uniform data structures
  Information is shared using standardised tags (PackTags), simplifying integration with systems such as MES, ERP and SCADA.
• Faster commissioning
  With a shared “language” across machines, setup and integration become quicker, more predictable, and more cost-effective.

Overall, PACKML improves consistency across operations while reducing downtime and integration complexity.

How PACKML works

PACKML is built around two key concepts: machine states and operating modes.

Machine States

These represent the different stages of a machine’s operation, such as:

• Stopped
• Starting
• Idle
• Execute (running)
• Stopping
• Holding / Held
• Aborting / Aborted
• Completing / Complete

Because all machines follow the same structure, it becomes much easier to understand what is happening across the entire line and respond consistently to issues.

Operating modes

These define how the machine is being used, for example:

• Automatic
• Manual
• Maintenance

Together, these states and modes create a clear and logical framework that improves coordination, simplifies training, and enhances overall efficiency.

PACKML in practice

In a PACKML-enabled packaging line:

• Integration with higher-level systems (MES, ERP, SCADA) is far more straightforward
• Equipment such as bagging, palletising and wrapping machines can communicate without complex custom programming
• New machines can be added with minimal disruption to the existing system
• Maintenance teams can diagnose faults more quickly using standardised alarms and messages

Key benefits for manufacturers

Adopting PACKML delivers several measurable advantages:

• Improved efficiency
  Machines operate in sync, reducing stoppages and miscommunication
• Greater flexibility
  Production lines can adapt more easily to new products or packaging formats
• Reduced costs
  Less engineering effort is required for integration and upgrades
• Simplified training
  Operators work with consistent interfaces across all equipment
• Better data visibility
  Standardised data enables more accurate performance tracking and analysis

PACKML also supports broader Industry 4.0 initiatives, where interoperability and real-time communication are critical.

Considerations and challenges

While PACKML offers clear benefits, adoption is still growing. Some common challenges include:

• The need for ongoing development to align with emerging technologies such as AI and industrial IoT
• Limited awareness or implementation across certain industries
• Older equipment that may require upgrades or adaptation

PACKML vs Traditional Packaging Lines

Aspect	Traditional Line	PACKML-Enabled Line
Integration	Complex, machine-specific	Standardised and simplified
Maintenance	Inconsistent alarms and diagnostics	Faster, uniform fault finding
Flexibility	Difficult to expand or modify	Easy to add new equipment
Engineering Costs	High due to customisation	Reduced through standardisation
User Experience	Different interfaces per machine	Consistent and intuitive

TMI’s approach to PACKML

TMI is actively incorporating PACKML into its solutions, including automatic bagging systems, palletising, and end-of-line equipment.

This involves aligning control architectures, HMI design, and data structures, while ensuring close collaboration between engineering, software, and technical teams.

For TMI, adopting PACKML is a strategic step towards delivering more integrated, efficient, and future-ready packaging solutions—designed to meet the demands of a connected, modern manufacturing environment.

Article adapted for USS Pactech
Original author: Oriol Miarnau, Lead Automation Engineer
Source: TMI (tmipal.com)

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