With the launch of the next-generation SIMATIC S7-1200 G2, the partnership between APS Industrial and Siemens is being strengthened to meet the rising demand for efficient control systems in Australia’s food and beverage sector. The S7-1200 G2 is a programmable logic controller (PLC), building on more than a decade of success with the original S7-1200 PLC.
The PLC automates machinery and processes by receiving inputs, executing logic-based instructions, and controlling outputs. Compared to the original, the S7-1200 G2 includes new enhancements and now achieves an overall footprint reduction of 25 per cent. The updated platform is suited to industries including food and beverage production, pharmaceuticals, packaging, and material handling where space, precision, and safety are key.
According to Automation and Drives business manager at APS Industrial, Steven Sischy, the S7-1200 G2 brings additional value with “enhanced communications and efficient motion control”. It also comes with pre-set function libraries that customers can download for faster operation. He explained that the S7-1200 G2 will focus on industries that rely on conveyors, packaging lines or filling capabilities.
PLC update
Manufacturers who possess earlier models and are considering an upgrade can benefit from the overhaul of Siemens’ PLC architecture. As well as speed, connectivity and space efficiency, the S7-1200 G2 also offers benefits in system integration and is programmed with TIA Portal.
“We’re moving from seven different CPUs to just four – two standard CPUs and two safety versions – which makes stocking and customer support much simpler,” said Sischy.
Sischy said that it has the capacity to handle more PROFINET I/O due to the increased expandability. Additionally, cybersecurity is native to the system, he said. APS Industrial has introduced (Near Field Communication) NFC for the first time, which allows instant fault diagnosis with an iPhone or Android with the right credentials, which maximises efficiency.
Smaller, safer, stronger
The unit’s smaller footprint is a targeted approach to increase performance and scalability. The system is aligned with the four pillars: performance scalability, flexible machine safety, efficient motion, and increased data transparency.
“This means a reduced footprint, allowing us to address up to 31 PROFINET devices across the network, compared to just 16 previously,” said Sischy.
Flexible safety features have also received a boost. The G2 has doubled its support for system boards and now includes dual PROFINET channels – separating machine communication from IoT or cloud connections. This helps support a clearer division between IT and OT systems.
With flexible machine safety, Siemens has gone from supporting one system board to two, providing more options to the customer. According to Sischy, communications have improved where the previous generation only supported one PROFINET channel. Now, a customer can connect to IoT or cloud-based systems, while the other links directly to devices on the machine. Customers also do not need to pay for additional software licenses if they have a fail-safe CPU. This change is now included as standard in the base software package.
The PLC’s motion control is one of the key enhancements compared to original models. Where the earlier generation had limitations to its integrated motion capabilities, the new system brings this functionality directly into the CPU, improving real-time control and synchronisation.
Sischy said that there has been a power dissipation reduction of 20 per cent for CPU 1212 and 30 per cent for CPU 1214, compared to predecessor products. Product performance increased by more than 100 per cent with a comparable weight (avg. increase <15 per cent) for all variants of CPU 1212 and CPU 1214 compared to its predecessor.
The new system also improves data visibility. With integrated NFC, operators can instantly access diagnostics wirelessly, reducing downtime and allowing quicker maintenance interventions.
For the future of food and beverage manufacturing
APS Industrial and Siemens have committed to helping food and beverage manufacturers with a smooth transition to automate their processes. Alongside the introduction of the S7-1200 G2, their commitment includes the offering of standard functions, motion control libraries and detailed application notes.
From beginning to end, the two companies provide tools to help customers get started, connect, configure, and even program the system. This whole process, as Sischy described, is to ensure that the S7-1200 G2 is more user-friendly and that the transition is fluid.
While the technology is newly launched, APS Industrial has already seen early adoption in food and beverage applications and is working on a water industry Remote Terminal Unit project. Sischy said that alongside these cases, the new system represents a journey into uncharted waters for APS Industrial and Siemens.
“Our key focus going forward remains on market segments where we haven’t been strong before – particularly OEM liquid filling applications. We now have the capability to pursue those opportunities,” said Sischy.
With the S7-1200 G2, APS Industrial and Siemens aim to empower manufacturers with a smarter, faster, and more transparent automation platform.