The standardisation of an industrial HMI system has become a key driver to enhance operational efficiency, reduce complexity, and deliver a consistent user experience across increasingly globalised packaging environments. In this context, Barcelona Packaging Hub highlights the collaboration between COPA-DATA and Volpak, where the zenon platform acts as the backbone to unify control, supervision, and human-machine interaction within a single environment.
COPA-DATA as the technological backbone
COPA-DATA, a specialist in industrial automation software, has developed zenon, a platform that integrates control functionalities, supervision (SCADA), and advanced connectivity within a single ecosystem. Its open architecture and compatibility with over 300 protocols enable seamless integration of different PLCs and third-party systems, supporting HMI standardisation without compromising flexibility.
This approach decouples the automation layer from the control system, reducing technical complexity and simplifying maintenance, while maintaining adaptability to diverse production environments.
Volpak’s challenge in managing industrial HMI interfaces
Volpak S.A.U., a global manufacturer of flexible packaging machinery (HFFS) and part of the Coesia Group, operates across multiple industries including food, beverage, pharma, and personal care. This diversity led to the use of different PLCs and multiple HMI interfaces tailored to each customer and project.
Over time, this heterogeneity resulted in system management challenges: increased engineering complexity, higher maintenance costs, and an inconsistent user experience across machines. The need was clear: evolve towards a standardised industrial HMI system capable of scaling while preserving customisation.
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A scalable, single HMI system with zenon
The implementation of zenon enabled Volpak to develop an architecture based on a single project capable of adapting to more than 30 machine types and thousands of different configurations. This approach centralises HMI development and significantly reduces variability across equipment.
Standardisation simplifies engineering processes, improves system consistency, and enhances technical support, while maintaining the flexibility required to meet specific customer and production line requirements.
Enhancing the user experience
The project was designed with a user-centric approach, resulting in a modern, consistent HMI interface across the entire Volpak and Enflex machine portfolio. This uniformity strengthens brand identity and improves usability on the shop floor.
The HMI system incorporates advanced touch navigation, including gestures such as swipe and zoom, as well as guided workflows that support operators in task execution. This reduces training time and accelerates machine adoption in production environments.
Advanced functionalities and engineering efficiency
One of zenon’s key differentiators within the industrial HMI system is the integration of technical documentation directly into the interface. Users can access manuals, electrical schematics, or spare parts lists without leaving the operational environment, even interacting with 3D models.
Additionally, the system includes intelligent alarm management assistance, providing contextual insights on root causes and potential solutions. Other features include CFR21 compliance with electronic signatures, centralised traceability, flexible reporting, and compatibility with standards such as PackML.
From an engineering perspective, zenon leverages a low-code / no-code approach, enabling control logic generation through configuration. This reduces manual programming, minimises errors, accelerates commissioning, and facilitates collaboration between technical and non-technical profiles.
Results and evolution of the industrial HMI system
The adoption of zenon has enabled Volpak to consolidate a fully standardised HMI system across its entire machine portfolio, while maintaining customisation capabilities. The result is a single scalable project with thousands of possible configurations built on a common technological foundation.
This approach not only optimises engineering and maintenance but also supports further integration of complete production lines within the Coesia ecosystem, delivering a unified view and enhanced operational control.
Overall, the collaboration between COPA-DATA and Volpak demonstrates how a standardised industrial HMI system can become a strategic asset to drive efficiency, scalability, and an improved user experience within the packaging industry.
If you would like to explore similar solutions or assess how to implement this approach in your organisation, you can contact the team at Barcelona Packaging Hub for expert guidance and access to a leading network of packaging professionals.