Our Solutions

  • Modular

    Modular

    RP900 Rotary Pick and Place Feeder

    Inserting three-dimensional products into a high-speed production line is difficult. At Pack-Smart Inc. we understand your challenges. That is why we have developed what is now the industry standard feeding system, the Rotary Pick and Place 900 Series. Feeding the world since 1996 the RP900 Series has tipped and packed everything from soap, coffee, video games, CD/DVD box sets, secure cards and more. This module allows you to accurately place varying three-dimensional shapes and sizes onto your production line with the unprecedented accuracy of ±1.6mm. You can now consistently do this at a rate of up to 250 products per minute. That’s 15,000 per hour! The articulating suction arms will rotate 360° and can be spaced to accommodate a wide range of sizes and with the self-contained, dual-vacuum system you can even manage objects weighing up to one pound.

    Features and Specs

    Speed: 15,000 u.p.h.
    Placement accuracy: 0.015"
    Magazine height: 30"
    Minimum material size: 1.25" x 1.25" x 0.01"
    Maximum material size: 20" x 9" x 0.47"
    Module width: 29.9"
    Module length: 33.9"
    Module length: 40.2"

    Benefits

    Capable of handling 3dimensional products and placing them with precision while maintaining the highest throughputs available.

    Available Functionalities/Add-Ons

    Automatic bottom alignment module for improved placement accuracy. Inline mag-encoding. Built in camera read and verification system.

  • Modular

    Modular

    RPS3000 Reciprocating Pick and Place

    RPS3000 Series Reciprocating Pick and Place module have been designed with versatility and flexibility in mind. The robust design makes is an ideal solution for feeding: trays, leaflets, sachet, clam shells and other odd shaped materials and products. The advantage of using the RPS3000 is the opportunity to automate the slow and costly process of feeding oddly shaped objects that may not be able to be fed through a Rotary Placer or conventional feeding applications. With an industry leading 80 C.P.M. (Cycles Per Minute), and multi-stream setups the Pack-Smart Intermittent Motion Pick and Place is will reduce manual labor requirements while increasing throughput. Optional Servo drives are available on the RPS3000 to allow for quick integration with third party systems, improved control features, and an increased top speed to 90 C.P.M.

    Features and Specs

    Speed: 80-90 c.p.m. (cycles per minute)
    Placement accuracy: +-0.02"
    Magazine height: 30"
    Drive: 100% servo driven
    Dimensions: Application dependent

    Benefits

    Designed for introducing large 3d objects into a production line. Ideal for multi-stream indexing applications.

    Available Functionalities/Add-Ons

    Multifold, coupons, plastic plates, plastic trays, corrugated trays, styrofoam trays, thermoform trays, foil trays glassine, card stock, plastic cards, sachets, CDs, DVDs, pharmaceutical inserts, injection molded parts

  • Modular

    Modular

    SF350 Smart Friction Feeder

    Our rugged, flexible, and extremely versatile feeding modules are essential to any production line. Built with the customer in mind and boasting the most advanced control system on the market Pack-Smart Inc.’s feeding modules are incredibly accurate and efficient with unmatched reliability. Our Pack-Smart Inc. Smart Friction Feeders come with a built-in motion controller. Motion controllers are equipped with customizable recipes which provide electronic accuracy to the thousands of an inch. They also have the capability to batch index, follow, and place multiple inserts on one host carrier. Seamless Integration with third party systems. External inputs outputs and RS232 available for quick setup and interface with third party controllers, such as PLCs or computers. The machined body with hardened drive shafts is designed for 24/7 operation. With precision bearings and quick belt, change features Pack-Smart Inc. has provided reliable solutions for the harshest environments.

    Features and Specs

    Speed: 1000ft/min
    Placement accuracy: 0.06"
    Magazine height: 18"
    Minimum material size: 1" x 1.5" x 0.0015"
    Maximum material size: 20" x 16" x 1"

    Benefits

    Cost effective, low maintenance, and incredibly reliable for tipping components, and feeding carriers.

    Available Functionalities/Add-Ons

    Autoloader up to 3m (10ft)
    Quick integration brackets
    Integrated mag encoding
    Integrated barcode scanner

  • Modular

    Modular

    FF500 Friction Feeder

    Employed in a spectrum of converting markets, the friction feeder is generally utilized for host product feeding applications. The pack-Smart friction feeder is a cost-effective solution for industrial automation feeding and inserting projects. From inserting a coupon to collating signature or paint swatches the Pack-Smart friction feeder offers flexibility and reliability in the most demanding environments featuring a 24/7 production schedule and Pack-Smart offers a number of sheet registration modules that are available to satisfy your needs. The feeding system is designed for high production speeds that demand equal spacing between products. The feeders are notably rugged paper feeding systems and the solid steel construction ensures stability and high performance even in the toughest environments, resulting in speeds of up to 600 products per minute. The pack-Smart feeders are capable of handling the lightest paper and are equally at home when dealing with heavy stock materials such as SBS board. They are also capable of feeding products in up to 4 continuous streams, are operator friendly and are ideal when product tracking/monitoring may be required in your production cycle.

    Features and Specs

    Speed: 200m.p.m. | 800u.p.m.
    Placement accuracy: 0.08"
    Magazine height: 15.7"
    Minimum material size: 4.3" x 4.3" x 0.008"
    Maximum material size: 19.7" x 27.6" x 2"
    Allowable product distortion: 0.008

    Benefits

    Ideal for large sheet feeding and carton feeding for windowing applications.

    Available Functionalities/Add-Ons

    Extended magazine
    Integrated barcode scanner
    Quick integration brackets

  • Modular

    Modular

    PG900 Flexo Pattern Gluer

    Pack-Smart’s Flexo Pattern Gluer module applies metered glue coatings to sheets or webs. PG900 units are equipped with state of the art servo technology and registration systems for integration with Pack-Smart or third party equipment. The distinct advantage of using the Flexo Pattern Gluing technique is the ability to produce unlimited shapes of glue and coatings without changing sheet direction. The Flexo Pattern Gluer module consists of two rollers allowing for glue application, fragrances or coatings. Precision ground deep etched cylinders eliminate slinging and increase the durability of the system. The Pack-Smart equipment has a 36” impression roller with a doctor (metering) roll. The gluing system has its own encoder that mounts, as well as, a product detection sensor. The system has available repeats of 36”, 18”, 12 and 9” (914.4mm to 229mm). The metering roll and the impression roll are mechanically connected through gearing so that they both run at the same surface speed. In order to skip a carrier to be glued or to account for a missing carrier the drum lifts by way of electronic control.

    Features and Specs

    Speed: 200 m.p.m.
    Accuracy: +-0.02"
    Minimum material size: 1" x 1" x 0.003
    Maximum material size: 20" x 24" x 0.01"
    Width: 40"
    Length: 36"
    Height: 25"

    Benefits

    The PG900 Flexo Pattern Gluer reduces glue slinging, has lower consumable costs, and provides its owners with the flexibility to produce an unlimited amount of glue patterns.

    Available Functionalities/Add-Ons

    Window affixing
    Media packaging
    Direct mail
    Burst and open sample fragrances
    Secure packaging

  • Modular

    Modular

    LB250 Label Applicator

    The Pack-Smart High-Speed Label Applicator easily, and efficiently applies a wide range of label types with unprecedented speed and accuracy. The Pack-Smart Label Applicator is capable of run speeds up to 250 p.p.m. while maintaining accuracy up to +- 1/32”. It incorporates two sensors, one to detect the presence of an oncoming carrier and one to verify the presence of a label. The height of the brush assembly at the bottom of the labeller is adjusted according to the carrier/card thickness. The brush itself applies light pressure to the label to ensure adherence. By combining our proprietary engineering designs with brushless servo technology our Pack-Smart Label Applicators require minimal maintenance in full-time manufacturing settings. Progressive features include an Electronic Gearing Module which permits product surface cam profiling, ensuring smooth application without blisters or wrinkles, even with mini labels.

    Features and Specs

    Speed: 250p.p.m.
    Accuracy: +-0.03"
    Web Width: 0.2" - 2.76"
    Minimum label gap: 0.15"
    Minimum label length: 0.4"
    Minimum gap between web and label (on each side): 0.125"
    Maximum product gauge: 0.25"
    Core: 3"
    Roll OD: 22"
    Width: 19.7"
    Length: 35.4"
    Height: 27.6"

    Benefits

    The LB250 Label Applicator is efficient, with low operating costs, and serves a variety of applications with a single module.

    Available Functionalities/Add-Ons

    RFID, EAS, mag stripe, Velcro, piggyback label, scratch off label, foam polygon hubs, pressure sensitive, scented labels, and more.

  • Systems

    Systems

    The HB924-6 Batching Unit with Inline Wrapping System

    The HB924-6 Batching with Inline Wrapping System feeds and batches product at speeds up to 72,000 products per hour when running dual stream configuration. With Pack-Smart’s state of the art, RP924-6 product is picked from the loader and placed with incredible accuracy into the batching unit below. The 6 x 360º articulating arms with suction cups are capable of handling a wide variety of 3-dimensional products from sachets, to paint swatches, inlays, CR80s, and rigid windows. At Pack-Smart our customers come first, that’s why we tailor each of our systems to our customers’ specific needs. We will never sacrifice the quality of your product for efficiency, instead, we will work hand-in-hand with you to develop systems that deliver the highest quality products at the greatest speeds available in today’s market. Our modular approach to engineering allows our systems to be stand-alone as well as integrated into existing lines, with the flexibility to add and remove features with quick and easy changeovers. On-site training and remote diagnostics from Pack-Smart guarantee that your employees will have the resources they need to succeed, ensuring your customer’s satisfaction, and your accountant’s.

    Speed

    Speeds up to 36,000 units per hour, 72,000 when utilizing dual stream.

    Versatility

    With the adjustable magazine and suction cups, the system is capable of handling a variety of products at high speeds.

    Quality

    With Pack-Smart's self-contained dual vacuum system the Rotary Pick and Place's suction cups are able to delicately handle product even at maximum speeds.

  • Systems

    Systems

    SC500 Secure SIM Card Packaging System

    At the forefront of the Secure & SIM card packaging industry is the SC500 Secure SIM Card Packaging System from Pack-Smart Inc. With speeds up to 13,000 products per hour, placement accuracy of ±0.020”, and uptimes upwards of 95%, this system will redefine your business. Our end-to-end solutions will reduce your labor costs, increase your throughput, and improve the quality of your finished product. Pack-Smart’s full data capturing and reporting system allows for the tracking of your product throughout the entire run. Rejected products are tracked, diverted, and a report is created detailing the issue. This allows our customers to diagnose and adjust, while still running with a 100% guarantee only verified products reach the delivery area. Utilizing a virtual machine platform, the 100% servo driven system provides unmatched reliability and flexibility to accommodate your customers’ product’s needs. Multiple Component Inserting | Package and Component Personalization | Full Data Capturing, Tracking, and Reporting. Modular design is at the core of all Pack-Smart systems. This building block approach to design allows our customers to tailor their system to their specific needs at any point in time. Prior to purchase, or after owning a system for several years, Pack-Smart is ready to help integrate additional features into your production line. Whether it be the personalization of cards, carriers, or both, we can offer that in-line in a single system pass. At Pack-Smart we work with our customers every step of the way and provide continuing support long after the Pack-Smart system has been delivered to your facility.

    Speed

    Speeds up to 13,000 units per hour. Optimize your process with our end-to-end solutions, including batching, wrapping, and labeling bundles.

    Versatility

    Card and component placement accuracy of 0.015" ensuring your finished product maintains its high-quality appearance.

    Quality

    With integrated verification systems your product is tracked throughout the production process. All errors are diverted, and remakes are initiated, guaranteeing a 100% verified product is delivered.

  • Systems

    Systems

    MM-1000 Mega Mailer

    Pack-Smart’s family of Mega Mailer systems are designed to give our customers the tools and flexibility they need to explore new manufacturing opportunities in the premium direct mail and specialty finishing world. By combining folding, gluing, sample and 3D object affixing and personalization in a single pass, our systems allow users to create unique and exciting direct mail and multi-substrate based direct mail projects. Built on a fiber optic network utilizing brushless servo-technology and state of the art motion control, our high-performance modular solutions enable unparalleled production flexibility and throughput. Our folding systems can be equipped with options that will produce folds in six directions without having to change the orientation of the product at speeds of up to 30,000 units per hour. The six-shaft arrangement of the scoring/perforation module executes a directional perforating, scoring or slitting process in-line with Pack-Smart feeders and vacuum transports. Directional scoring, perforating, and slitting is achieved by employing three sets of independently adjustable precision ground, hardened shafts. Due to the high quality and precision of our scoring components, our systems achieve scores that exceed the press quality of conventional letterpress applications. Scores formed on Pack-Smart systems are crisp and eliminate cracking after folding even on difficult stocks. The Pack-Smart VC Series vacuum transport is ideal for all custom tipping, folding & gluing and imaging applications. Fully adjustable vacuum volume, selectable zones and easy, proprietary belt tracking systems coupled with electronic gearing technology make setup a snap. Along with an industry best drive system capable of running at speeds of 200 mpm Pack-Smart’s vacuum transports are an essential part of your mail finishing solution. We also offer universal and automatic pile or shingled delivery systems for all Pack-Smart mailing systems. All units come with mechanical and electronic height adjustment and batch size control. Adjustable shingling rollers ensure that finished products are delivered in a perfect stack.

    Speed

    Complete your specialty print finishing process at the highest speeds available, 30,000 products per hour.

    Versatility

    Personalize each piece with inline DOD ink jets with up to 600DPI, or generate print and apply labels for affixing during the production process.

    Quality

    With Pack-Smart's focus on modular design your system can complete all necessary processes in a single system pass; Folding, gluing, scoring, tipping, personalization, and more.

  • Systems

    Systems

    CP2500-1 Card Personalization System

    The CP2500-1 from Pack-Smart Inc. is the industry’s most robust and flexible card personalization solution. With speeds up to 30,000 products per hour, it is ideal for all your closed, secure, and open loop needs. By combining advanced features, uncompromising quality, top throughput, reliable reporting, and an operator-friendly interface the CP2500-1 can achieve any goals. The CP2500-1 features a high-speed pick and place feeding system. This system allows for excellent handling of a diverse number of card formats; CR80s, M6 hang tags, and many custom shaped cards. It’s no surprise that it is the preferred choice of global leaders with complex and unique projects, substrates, shapes, and inline processes. The CP2500-1 runs on Pack-Smart Inc.’s Virtual Machine software/hardware platform, backed up by a rugged fibre-optic network and customizable report compliance interface.

    Multiple Component Inserting | Package and Component Personalization | Full Data Capturing, Tracking, and Reporting Modular design is at the core of all Pack-Smart systems. This building block approach to design allows our customers to tailor their system to their specific needs at any point in time. Prior to purchase, or after owning a system for several years, Pack-Smart is ready to help integrate additional features into your production line. Whether it be the personalization of cards, carriers, or both, we can offer that inline in a single system pass. At Pack-Smart we work with our customers every step of the way and provide continuing support long after the Pack-Smart system has been delivered to your facility.

    Speed

    Speeds up to 30,000 units per hour. Optimize your process with our end-to-end solutions, including batching, wrapping, and labeling bundles.

    Versatility

    Personalization features include various magstripe label affixing, 1D and 2D barcode printing, and scratch off label application.

    Quality

    With integrated verification systems your product is tracked throughout the production process. All errors are diverted, and remakes are initiated, guaranteeing a 100% verified product is delivered.

  • Systems

    Systems

    IIA-175 Inline Insert Affixing System

    The Pack-Smart IIA-175 Inline Insert Affixing System is fully integrated and the most successful way to combine multiple pre-folded Pharmaceutical inserts/outserts in variable stack counts. The system comes in two standard configurations, inline and hybrid, and employs Pack-Smart’s industry leading RP912 Series Rotary Pick and Place feeders. The IIA-175 fastens the multiple inserters together at speeds up to 13,000 finished products per hour. This incredible system is equipped with a barcode verification module coupled a with diverting container to ensure inadequate or incorrect sets are quartered. For delivery users have the option between a shingled delivery module or vertical stackers with a tray loader to allow for easy loading at the discharge stage. Additionally, systems can be fitted with auto-loaders and primary pick and place modules for offline applications.

    Speed

    Speeds up to 13,000 units per hour. Optimize your process with inline folding & gluing.

    Versatility

    Place components with unparalleled accuracy, +-0.02". Place cards, T&Cs, booklets, and 3d samples with ease.

    Quality

    With integrated verification systems your product is tracked throughout the production process. Maintain accuracy with version control, multiple language inserts, and other complex tracking requirements to ensure the right product ends up in the right package.

  • Systems

    Systems

    SS-250 Barcode Verification System

    When 100% identification, validation, and recording of SKU/version control are a requirement, Pack-Smart’s Smart Scan 250 is the answer. Pack-Smart’s high-speed continuous feed system with up to 60,000 u.p.h. delivers on capture, decoding, validating or diverting barcoded product. The Pack-Smart Barcode Scanner is capable of reading Code-128, DataMatrix, UPCA/B, EAN-13, PDF-417 and QR-Code bar-codes. The SS-250 is an ideal solution for high-speed barcode reading on a wide variety of products such as folding cartons, blister cards, pharmaceutical packaging, CR 80 cards and just about any other application that requires 100% product version accuracy.

    Speed

    Verify products at the highest speeds available, 60,000 products per hour.

    Versatility

    Divert rejected product to ensure only 100% verified product reaches the delivery conveyor.

    Quality

    Pack-Smart's multiple feeding options allow for a wide range of different products to verified using a single system. Combined with a machine up-time of 98% this system is undeniably efficient.

Why Should You care?

Our automation solutions run at 4x the industry standard. We truly are dictating the speed of business.

Our solutions have 3x the accuracy when compared to the next closest competitor and we don’t sacrifice on speed.

 


Our overall equipment effectiveness(OEE) is above world class. No competitor even comes close to matching our capabilities.

Our commitment to speed, accuracy, and efficiency allows us to consistently produce brand changing product volumes.