Digitalization is transforming how companies design and operate their production systems. In the packaging sector, Pester PAC Automation GmbH is a shining example of this evolution by integrating 3D visualization into a modern, intuitive human-machine interface (HMI).
Background: A Global Leader in End-of-Line Packaging
Pester PAC Automation, a family-owned company with a worldwide presence, is a major player in providing end-of-line packaging solutions. For over 45 years, it has been innovating in the pharmaceutical and consumer goods sectors, with a 60/40 activity split. Despite modernization in user interfaces (UI), traditional HMIs often lack operator-centric features, relying heavily on text and offering limited graphical content.
Objective: A More Intuitive HMI with 3D
Since 2016, Pester has embarked on an ambitious challenge: equipping all its packaging machines with a user-friendly HMI that integrates high-performance 3D visualization. The goal is to provide operators with a lightweight and accurate digital twin that mirrors the real state of the machine. This approach enables:
- Intuitive fault localization.
- Technical documents directly linked to 3D components.
- Spare parts to be ordered in one click directly from the 3D view.
Technical Challenges: Combining Traditional HMI with 3D
Implementing a high-performance 3D HMI was no easy feat. The hardware designed for \"traditional\" HMIs is not always optimized for 3D graphics. Additionally, Pester had specific requirements, necessitating custom extensions for the 3D viewer.
- Web compatibility: The initial solution lacked the flexibility to display 3D across different platforms.
- User-friendly API: A programming interface was needed to enable easy integration and customized features.
By recognizing the potential to use the same 3D visualization across multiple tools (spare parts catalog, product configurator, etc.), Pester ultimately chose Kisters’ 3DViewStation, despite a higher initial cost.
The 3DViewStation Solution: A Lightweight, High-Performance Digital Twin
With 3DViewStation’s powerful API, design data was transformed into a lightweight and highly efficient digital twin. The integration of the WebViewer version into the HMI enabled:
- Ultra-fast loading of 3D models.
- Interactive display of detailed component information.
- Instant access to documentation and spare part orders.
Tangible Results: Enhanced Clarity, Reduced Errors
Since autumn 2022, machines equipped with 3DViewStation have been deployed at numerous client sites. In parallel, Pester offers:
- A 3D-integrated spare parts catalog for simplified searches.
- A preventive maintenance solution leveraging 3D visualization.
- Future integration of 3D graphics into its online product configurator.
Case Study: During an error, the machine is displayed semi-transparently, with the defective component highlighted. With one click, the operator understands the root cause of the issue and receives instructions to resolve it—eliminating the need to search through complex manuals.
A Successful Partnership with Kisters
By leveraging 3D visualization and selecting 3DViewStation, Pester PAC Automation has set itself apart with a user-centric HMI. The feedback has been overwhelmingly positive, as highlighted by Ralf Abler, Director of Innovation & Digitalization at Pester PAC Automation GmbH, who states:
“I have never regretted collaborating with Kisters to design a new 3D visualization for our HMI. From the very beginning, the synergy and understanding were perfect!”
With this approach, Pester meets the reliability and productivity needs of its clients while paving the way for new features, such as a 3D-enriched product configurator. The result: an ultra-efficient packaging solution and a vastly improved user experience.