The VARIBOX® is a robust, reusable alternative to traditional standard IBCs and is used primarily in the chemical industry for the safe storage and transport of liquid products. Thanks to its durable construction and the ability to reuse containers multiple times in closed-loop systems, it supports resource-efficient and effective logistics.
At the same time, the reusability of packaging is becoming increasingly important due to the new EU Packaging and Packaging Waste Regulation (PPWR), as it promotes sustainable packaging solutions and a circular economy.
With the Packwise Smart Cap ,VARIBOX containers can also be easily digitized. The sensor enables the monitoring of relevant container data, which is processed via Packwise Flow 2.0 and can then be used for transparent and more efficient inventory and delivery planning. The CVH Chemie-Vertrieb Group’s success story demonstrates how VARIBOX containers can already be successfully combined with Packwise technology
Installing the Packwise Smart Cap is straightforward and can be done in just a few simple steps. In this step-by-step guide, we’ll show you how to install the Packwise Smart Cap on a VARIBOX and what to keep in mind during the process.
VARIBOX containers are used in industrial supply chains, particularly where liquids need to be stored and transported safely. It is important for companies to maintain an overview of their containers and their fill levels at all times.
Without digital support, monitoring is often done manually. Employees must check containers on-site, document fill levels, and pass on information to the relevant departments. Especially when dealing with a large number of containers or multiple locations, this process can be time-consuming and prone to errors. This is where Packwise comes in: The Smart Cap collects relevant container data and makes it available via the Packwise Flow software. This gives companies a better overview of their inventory and allows them to plan refills and deliveries more proactively.
The first step toward digital container monitoring is the proper installation of the Smart Cap.
The Packwise Smart Cap is designed to be installed without significant technical effort.
Before the Packwise Smart Cap can be installed on the VARIBOX, the top cover of the container must first be removed to expose the container surface underneath. To do this , first loosen the four stacking rods at the corners of the cover. To do this, remove the corresponding protective caps and unlock the stacking rods by turning them 90 degrees counterclockwise using a 12-mm Allen wrench. The four stacking rods can then be pulled straight up and out. Once all four stacking rods have been removed, the top cover of the VARIBOX can be taken off. The underlying container surface is now fully accessible and can be prepared in the next step for installing the Smart Cap.
Before attaching the Packwise Smart Cap to the VARIBOX , the intended mounting surface must be carefully cleaned . Take special care to ensure that the surface is completely free of dust, dirt, grease, and other residues . Contaminants can impair the adhesive surface’s bonding ability and prevent the Smart Cap from remaining securely attached to the container over the long term . After cleaning , the surface should be completely dry . A clean, dry , and as level as possible mounting surface is essential for reliable sensorattachment .
Before mounting the Packwise Smart Cap on the VARIBOX, the sensor must first be activated. To do this, remove the small magnet located on the side of the Smart Cap prior to installation. Removing the magnet activates the Smart Cap, which is then ready to collect relevant container data and make it available for digital tracking. After activation, the sensor can be prepared for subsequent installation on the VARIBOX.
Before attaching the Smart Cap to the VARIBOX, the sensor should be prepared for installation. On the underside of the Smart Cap is a white adhesive surface covered by a protective film. Carefully remove this film to expose the adhesive surface. Care should be taken to avoid touching the adhesive surface with your fingers if possible. Dirt, dust, or other residues can impair adhesion and thus make attachment more difficult. After removing the protective film, the Smart Cap is ready for installation.
The next step is to determine the position where the Smart Cap is to be attached. The top of the VARIBOX provides a suitable mounting surface for this purpose. It is important that the selected area be as flat, clean, and dry as possible. Uneven surfaces or dirt can prevent the adhesive surface from making full contact. In addition, the position should be chosen so that the Smart Cap is not obstructed by the surrounding metal frame or other components. Careful positioning is important to ensure that the sensor can be securely fastened and is as well protected as possible during subsequent operation.
Once the appropriate position has been selected, the Smart Cap can be attached. To do this, place the sensor with the exposed adhesive surface facing down on the designated spot. Then press the Smart Cap evenly against the container surface for 5–10 seconds. In this step, it is important to attach the sensor directly to the intended position and avoid moving it afterward. Thanks to the adhesive mounting, the Smart Cap can be installed on the container without any additional mechanical modifications. Drilling or screwing is not necessary for this installation step.
After installation, check to ensure that the Smart Cap is securely attached to the VARIBOX. Pay particular attention to ensure that the sensor is fully in contact with the designated surface and that there are no visible signs of detachment along the adhesive surface. Once the Smart Cap is properly secured, the mechanical installation is complete. The container is now ready for the subsequent digital setup.
After the mechanical installation, the next step is to digitally integrate the Smart Cap. For this purpose, Packwiseprovides the Packwise Flow Link app, which is available on the Google Play Store and the Apple App Store. Using the app, the Smart Cap can be assigned to the respective container and linked to the Packwise Flow software. This ensures that the collected data can be assigned to the correct container.
In Packwise Flow 2.0, the available sensor data is then clearly displayed. This allows companies to digitally view relevant information—such as fill levels and container movements—and use it for their operational processes. The combination of the Smart Cap and the software thus lays the foundation for cross-site, data-driven container monitoring.
The Packwise Smart Cap can be used not only on the VARIBOX model presented here but also offers options for digital fill-level monitoring on other VARIBOX models. Depending on the container model, the Smart Cap can be mounted in different positions to reliably capture relevant container data and make it available via Packwise Flow 2.0. The following illustrations show additional examples of VARIBOX models that utilize the Packwise Smart Cap.
A distinctive feature of the VARIBOX models is that the Packwise Smart Cap is mounted in different positions depending on the container type. While the sensor is mounted directly on the top of the Varibox cover on some models, on other variants it is mounted under the outer cover directly on the container or on the inside of the hinged lid, as if “clamped” in place.
These different mounting options make it possible to adapt the Smart Cap to the specific design of the VARIBOX.
Installing the Smart Cap transforms a conventional container into a digital source of information. Instead of relying solely on manual checks or estimated consumption figures, companies can use up-to-date container data for their planning. This offers various advantages, especially for larger container fleets.
Greater transparency regarding fill levels: Companies can remotely monitor available inventory and gain a better overview of the supply situation.
More efficient refill and delivery planning: Real-time fill level data helps identify refill needs early on. This allows for better planning of deliveries and helps avoid unnecessary trips.
Less manual monitoring effort: Digital monitoring reduces the need to regularly check each container on-site. This saves time and reduces the workload on employees.
Centralized data management with Packwise Flow 2.0: The collected information is consolidated in a digital environment. This enables companies to monitor their container inventories across multiple locations and make data-driven decisions.
The Smart Cap thus not only provides measurement data but, in combination with Packwise Flow 2.0, creates real added value for the entire container management process.
Installing the Packwise Smart Cap on a VARIBOX demonstrates just how easy it can be to get started with digital container monitoring. With the right preparation, a suitable mounting position, and careful installation, the sensor can be attached in just a few steps.
The real added value comes from the integration with Packwise Flow 2.0. The software makes the collected data actionable and helps companies manage inventory more transparently, streamline delivery processes, and identify cost-saving opportunities. This turns a simple sensor installation into an important step toward a smart, connected supply chain.
Our experts are happy to assist you with customized installation instructions and practical guidance tailored to your containers and requirements. Schedule an appointment now and discover the possibilities of digital level monitoring with Packwise!