News release | August 2026

ZRAY has standardized its entire automatic carton erector range on an Industry 4.0-ready control architecture with built-in remote diagnostics. Every machine shipped after September 2026 includes native OPC UA, MES/ERP connectivity, and a secure remote service channel — without requiring any third-party gateway hardware.

What “Industry 4.0-Ready” Means on a Carton Erector

Industry 4.0 can sound abstract for a machine that erects boxes. In practice, the new standard affects five concrete capabilities:

1. Native OPC UA Server

Every new erector runs an embedded OPC UA server. Plant SCADA, MES, or any OPC UA client can read machine status, cycle counts, alarm lists, and production counters directly — no extra PC, no custom driver, no middleware license.

2. MES/ERP Data Exchange

The machine can report per-shift production data (cases erected, rejects, uptime, downtime codes) to the MES in a standard format. The PLC buffers 30 days of data locally, so a network drop does not lose production history.

3. Secure Remote Diagnostics

Each machine includes a built-in secure remote service channel (VPN-over-TLS, no open ports). With customer authorization, a ZRAY engineer can:

• Read the full alarm history and trend charts.
• Review machine parameters against the original acceptance data.
• Upload recipe tweaks (e.g., a folding force profile for a new board grade) after a remote test cycle.
• Run a guided diagnostic session with the local maintenance team.

4. Predictive Maintenance Data Stream

The machine streams wear-related counters — vacuum cup cycles, folding shoe cycles, tape head operations — to the cloud or plant server. The data feeds the same analytics used in the IoT sensor program, giving maintenance teams early replacement signals instead of reactive failures.

5. Cybersecurity Baseline

The control architecture follows the IEC 62443-4-2 security level SL1 baseline:

• Role-based access (operator / maintenance / engineer / service) with password policies.
• Signed firmware updates — only ZRAY-signed images are accepted.
• Audit log of all parameter changes and access events, exportable for quality audits.

Compatibility

The Industry 4.0 control architecture is now standard across the entire range: single-piece case erector, three-piece case erector, double-head high-speed case former, and the rigid box capping machine.

For machines installed since 2022, the upgrade is available as a control cabinet swap — one day on-site, including PLC, HMI, and the network module, with all recipes migrated from the old unit.

What It Solves for Your Team

• Maintenance: your CMMS gets machine data without manual data entry; alarm lists arrive automatically.
• Engineering: remote recipe tuning means a new board grade can be commissioned from our engineers’ desks before they fly to your site — typically saving one site visit per new grade.
• Management: real uptime, OEE, and reject data per line replace spreadsheet estimates.
• Quality: the audit-log export supports ISO 9001 and customer quality audits with documented machine history.

Data Sheet Snapshot

Availability

Industry 4.0 control is standard on all new orders and available as a field upgrade now. Ask your ZRAY contact for the integration guide (OPC UA node map, MES data dictionary) before your next plant automation meeting.

Request the Industry 4.0 integration guide or message us on WhatsApp at +86 13681839278.