CF1220-LTE control system
The CF1220-LTE Control System is a focused retrofit designed to modernise the control layer of Cremer CF1220-family machines while retaining the original wiring and mechanical platform.
At its core is a XIAC-designed interface control board with a piggy-back PLC. This creates a clean separation layer between legacy electronics and modern control — allowing new features and diagnostics to be added without disruptive rewiring.
The upgrade can be supplied with an HMI for mounting on the OEM stainless steel post, or with a compact hand-held HMI (HHT size) on a curly cord.
Modern control + diagnostics while keeping the machine’s proven architecture intact.
Minimum system components
- XIAC signature interface control board (separation layer between modern control and OEM electronics)
- Piggy-back PLC (sequencing, diagnostics, feature control, integration)
- HMI option: post-mounted on OEM stainless post or compact hand-held HHT-style (curly cord)
Hand-Held Terminal (HHT) replacement
The CF1220-LTE system can be supplied with a modern hand-held terminal (HHT) designed as a direct dimensional replacement for the original Cremer unit.
Left: XIAC 4.3" colour touchscreen HHT Right: Original Cremer keypad terminal
- 4.3" colour touchscreen display
- Same external dimensions as OEM hand-held terminal
- Curly cord connection (compatible mounting concept)
- Same functionality as the post-mounted HMI
- Standard 100-recipe structure
The unit preserves the familiar operator workflow while providing modern visual feedback, expanded diagnostics, and structured parameter handling.
CF1220-LTE Core benefits
- No need to replace any cables
- Installation typically in half a day (including cleaning & verification)
- Maintain 100% counting accuracy
- Increase output by 10–15%
- Long-term serviceability and parts availability
Performance features
-
AFC (Automatic Feed Control)
Adjusts product feed so the machine continuously runs at its optimum point. -
Staged memory flaps
Prevents sudden mass discharge by opening flaps in stages — producing smoother product flow and reducing nozzle congestion. -
Fast bottle reject
Saves production capacity by minimising the recovery penalty when a bottle is rejected off the conveyor. -
Speed nozzles (optional)
Can be used where product flow is smooth enough to avoid dipping-nozzle motion — reducing indexing time.
Speed nozzles are not universal: some products still benefit from a dipping nozzle that covers the bottle neck to prevent spill. Where suitable, speed nozzles remain down and do not cover the bottle neck, eliminating the lift step before indexing.
Beyond mechanical and flow optimisation, the CF1220-LTE introduces structured PLC-level production intelligence designed to improve throughput stability, quality control, and full-line integration.
Advanced PLC feature set
The CF1220-LTE control system introduces a structured range of programmable production and quality-control features beyond standard OEM functionality.
AFC – Automatic Feed Control
When enabled, AFC automatically adjusts the amplitude of the vibratory plates to maintain optimum product flow.
- Maintains stable channel utilisation
- Reduces overload conditions
- Improves throughput consistency
BPM timer – Bottles Per Minute limiter
When enabled, the operator can define a maximum BPM value. The machine will not exceed this rate, even if technically capable.
- Improves downstream bottle flow
- Stabilises conveyor discharge
- Prevents overload of capping or labelling equipment
- Balances full production line performance
Staged memory flap release (configurable)
The HMI provides a “memory flaps release time” parameter. The PLC calculates staggered opening intervals so that flaps open sequentially rather than simultaneously.
- Smooth vertical product stream
- Reduced nozzle congestion
- Improved high-speed stability
Double product – Double count logic
When two products pass a channel almost simultaneously and overlap, the PLC detects this condition. The operator can define how the system responds, including counting the overlapped products as two pieces.
- Allows higher vibratory plate population
- Increases counting capacity
- Reduces unnecessary reject events
Product chip filter
The counting protocol can be configured to ignore small product fragments (e.g. chips up to approximately 4 mm).
- Reduces false counts caused by minor product chips
- Not intended for filtering broken half-tablets
Reject management controls
- Rejections per 4-minute timer: operator-defined maximum number of rejects within a 4-minute interval. If exceeded, the machine stops for investigation.
- Maximum bottles on reject table: machine pauses if the reject table reaches a defined limit to prevent accumulation.
- Initial reject count on restart: programmable number of bottles automatically rejected after idle periods (e.g. lunch break) to account for possible slow first activation of memory flaps.
Instruction video: upgrade installation
Installation overview video for the CF1220 upgrade / retrofit.
Prefer to open it in YouTube: watch here →
Instruction video: upgrade installation (HHT version)
Installation overview for the CF1220-LTE+ upgrade using the hand-held terminal (HHT) version.
Prefer to open directly in YouTube: watch here →
Field installation example
Recently installed CF1220-LTE upgrade at a customer site in the USA. Direct replacement of the original Cremer terminal — same mounting concept, modernised control architecture.
Left: Original Cremer terminal Right: XIAC CF1220-LTE HHT replacement (installed)
Support
If you have a problem with a Cremer CF1220 (TQ1220), CVC1220, CF1230 or CF830 automatic tablet counter, you can contact XIAC for repair, fault finding, diagnosing, spare parts, upgrades, instructions, commissioning, and anything else you may be interested in.