Wenglor Introduces Contrast Sensor for Reliable Print Mark Detection

Even in highly automated production lines, a small sensor often carries a big responsibility. On high-speed packaging lines, one missed print mark can throw off a variety of common operations, ranging from sealing, cutting, or labeling, which can lead to waste, downtime, and rework.

Wenglor’s new P1MW series contrast sensors are designed to make the print mark detection simpler and more reliable. The new sensors are built to detect even faint contrasts while holding up under changing materials, colors, and speeds.

The P1MW contrast sensors are built to detect even the smallest of print marks on moving packaging film lines. Image used courtesy of Wenglor

P1MW Contrast Sensors

Wenglor’s new P1MW series of contrast sensors is designed for high-volume print mark detection. They are suited for packaging, labeling, and other manufacturing processes that depend on repeatable precision and minimal setup time.

The P1MW sensors are built to handle small shifts that naturally occur in continuous, everyday production. This jump detection feature identifies sudden changes in contrast, ensuring reliable mark detection even when materials or colors vary from batch to batch. The sensors are also equipped with dynamic teaching, allowing the sensors to automatically tune themselves during operation by adjusting to new conditions.

A focused, uniform light spot enables detection of even the smallest print marks, while the bright white light and monochrome evaluation help the sensors maintain accuracy across different color combinations. That level of precision matters on fast-moving packaging lines, where even a one-millimeter shift can affect cut placement or sealing accuracy.

A compact P1MW contrast sensor detects print marks on tea packaging films to keep folding, gluing, and cutting consistent from package to package. Image used courtesy of Wenglor

Compact Print Mark Detection

With a 54.5 x 27 x 16 mm footprint, the P1MW can easily fit into machines with limited space, making it ideal for compact packaging machines. Its RGB status indicator gives quick visual feedback right on the device, and IO-Link 1.1 enables engineers to configure settings, read data, and duplicate parameters digitally. The series includes Wenglor’s free wTeach2 software, which provides a clear view of all sensor data.

The P1MW series currently has two models, the P1MW001 (PNP output) and P1MW002 (NPN output), which offer the same optical and processing performance, depending on their control system requirements. Whether a machine uses sourcing or sinking inputs, there’s a compatible model that integrates easily without additional converters or rewiring.

Wenglor currently offers two models in the P1MW series: the P1MW001 (PNP) and the P1MW002 (NPN). Image used courtesy of Wenglor

Process Reliability in Packaging

The P1MW series can be used in a wide range of packaging systems, including tea bag folding machines, chocolate wrapping equipment, and sachet fillers. In each setup, the sensor’s compact light spot and adaptive detection algorithms can be used to help it recognize print marks even on glossy or colored materials. At higher conveyor speeds, the sensor keeps timing and alignment stable between marks and machine movement, ensuring that sealing and cutting remain precise from one package to the next.

Reliable sensors are what keep automated systems running without interruption. The P1MW series is built to improve mark detection, adapt to color shifts, and reduce the need for constant readjustment. It is a practical, steady upgrade that helps packaging lines maintain accuracy and avoid unnecessary stoppages, which in most facilities is the kind of improvement that matters most.