Australian packaging machinery leader Packserv has unveiled its PLC-controlled twin-head filler — a compact, Industry 4.0-ready solution designed specifically for small to mid-sized manufacturers. Recently featured in Packaging News, this breakthrough machine combines automation, adaptability, and real-time data monitoring to help SMEs scale production without excessive capital investment.
Originally published 23 July 2025 by Packserv. Read the original article on Packaging News.
Packserv has released its PLC-controlled twin-head filling machine, a first of its kind, designed and manufactured in Australia specifically for small to mid-sized (SME) manufacturers. Compact in design for space-conscious manufacturing environments, it brings Industry 4.0 technology into a practical format that makes sense for everyday production.
Packserv managing director, Nathan Wardell, said digital technologies, like Industry 4.0 and 5.0, along with evolving sustainability standards, are shaping the future of manufacturing.
“However, for many SMEs, adoption is a key challenge,” said Wardell.
“The upfront investment can be steep, and many systems are overly complex or simply too large for small-scale operations. It’s not that the technology lacks value, it’s that it often isn’t practical.”
At the same time, SMEs are contending with a rapidly changing workforce. That means training is a constant, and equipment must be intuitive, easy to learn and quick to operate with minimal downtime between applications.
The new Packserv filler has been designed with these realities in mind. Operators engage with the machine through a simple HMI touchscreen. Core parameters, such as fill volume, speed, and nozzle configuration, are easily accessible through preloaded settings. Switching between products is fast and streamlined, eliminating manual adjustments and reducing waste from trial-and-error setups.
Real-time data acquisition monitors cycle times, resource usage and energy consumption for improved operational efficiency. The machine also features smart sensors and data monitoring to maintain consistent fill levels, even when container shapes or product viscosities change. This automatic adaptability results in fewer spills, fewer rejects, and greater overall efficiency.
“What SMEs need is machinery that’s smart, user-friendly, and operator-focused,” said Wardell.
“In addition, the modular design of the machine means that it can easily be integrated with other machines in the production line such as capping, labelling, and conveying – improving productivity and efficiency.”
Because the machine was designed and developed in-house, the intellectual property stays in Australia, supporting local innovation, manufacturing and jobs. Spare parts and technical support are readily available, minimising any downtime.
For SMEs looking to move beyond manual or semi-automated systems, the Packserv twin-head filler offers a practical and affordable entry point into the world of smart manufacturing.
By focusing on the features that matter, such as automation, ease-of-use, adaptability, real-time monitoring, and data, Packserv has created a scalable solution that supports sustainable growth without excessive capital investment.
“Innovation shouldn’t be out of reach,” said Wardell.
“By making advanced technology more attainable and cost-effective, we’re helping SMEs strengthen their operations and stay competitive. Now more than ever, it’s vital to back local manufacturers and choose Australian-made.”
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