• Speeds up to 16,000 PPH
• Card affixing accuracy of ±0.5 mm in portrait and landscape orientation
• Carrier fold support for pre-fold, inline, half fold, Z fold, C fold, and barrel fold
• Real-time data matching, tracking, validation, and end-to-end reporting
• On-the-fly product remake to keep production in sequence without stopping
• 100% servo-driven architecture with digital brushless servo motors

• Remote virtual machine platform and system diagnostics
• Card reading support for OCR, barcode, magstripe, and contactless formats
• Carrier reading support for OCR and barcode
• Front, back, and plow folding configurations Integration with Delta-X Trust for production tracking, validation, reconciliation, and reporting
• Designed for 24/7 production environments with quick change between workflows

• Segment: Cards
• Primary function: Card & carrier matching with data validation
• Maximum speed: 16,000 PPH
• Daily capacity: More than 350,000 cards per day
• Card affixing accuracy: ±0.5 mm
• Orientation support: Portrait and landscape
• Fold types: Pre-fold, inline, half fold, Z fold, C fold, barrel fold

• Drive architecture: 100% servo driven with digital brushless servo motors
• Data handling: Real-time matching, tracking, validation and end-to-end reporting
• Remake capability: On-the-fly product remake while maintaining production sequence
• Operator requirement: 1 operator + 1 person reloading + 1 person on delivery
• Diagnostics: Remote virtual machine platform and system diagnostics
• Uptime: 95% or better

• Carrier feeding: Introduces letter, legal, or custom carriers into the MA-500 transport sequence.
  
• Carrier registration: Positions each carrier before scoring, glue application, card attachment, and folding.
  
• Vision inspection: Verifies carrier presence, orientation, and critical printed or registration features before the carrier moves downstream.

• Scoring and slitting: Applies the required score marks or preparation features for the selected fold configuration.
  
• Fugitive glue application: Applies temporary adhesive points to secure the card while allowing clean end-user removal.

• Card feeding and data read: Feeds cards into the system and reads required card data using OCR, barcode, magstripe, or contactless technologies.
  
• Data read and write: Supports required card and carrier data validation within the production workflow.
  
• Pick and place robotics: Transfers and positions cards for controlled attachment to the prepared carrier.

• Card attachment: Affixes the matched card to the correct carrier in the required position and orientation.
  
• Placement inspection: Verifies card position after attachment to support ±0.5 mm placement accuracy.
  
• Diverting: Removes mismatched, rejected, or non-conforming products from the production sequence.

• Label application: Applies required pressure-sensitive labels, activation labels, or program-specific labels where required.
  
• Label placement inspection: Verifies label presence and position before the carrier advances.
  
• Folding options: Supports pre-fold, inline, half fold, Z fold, C fold, and barrel fold configurations.
  

• Conveying: Maintains controlled product movement through the folding and delivery sequence.
  
• Delivery: Transfers finished carriers for downstream mailing, fulfillment, or pack-out.

Real-time matching

• Connects card and carrier data during production to protect match integrity.

Tracking and validation

• Tracks product status through the MA-500 workflow and validates critical production events.

Camera scanning

• Supports inspection and verification logic tied to carrier, card, label, and placement control.

End-to-end reporting

• Provides production records for job review, reconciliation, and operational accountability.

On-the-fly remake

• Supports remake of rejected products while helping maintain production sequence.

Remote diagnostics

• Supports system visibility, troubleshooting, and production support.

• High-speed vibratory bowl for product alignment
  
• Redundant buffering systems to maintain continuous operation
  
• Advanced rotary motion pick and place for precise product placement

• Integrated weighing and scanning for accurate quality control
  
• Servo-controlled system for flexible and efficient operation

• Capacity: Up to 2000 finished bundles per hour
  
• Label placement accuracy: ±1 mm

• Rejection rate: Less than 2%
  
• Power requirements: 230 V AC, 3 phase, max 30 A

• VF900 Vibratory Bowl Feeder: Utilizes vibration technology to orient and sort products efficiently, ensuring they are correctly sequenced for packaging.
  
• Axode Camera System: Scans and verifies each product for correct sequence and range, enabling accurate tracking and initiation of variable print and apply label content.

• Transport Conveyor: Moves the verified products into the batching module, maintaining a consistent flow to optimize the handling process.

• BC20-03 Batching Module: Collects products and organizes them into specified counts or sequences, preparing them for bundling.
  
• Alma Flow Wrapper: Encases grouped products in a protective wrap, securing them for the labeling process.

• PAP3000 Print and Apply Labeler: Automatically generates and applies labels to each bundle, ensuring each package is accurately labeled with essential tracking information and product details.

• Weigh Check Module: Conducts a detailed weight verification of each packaged bundle to ensure it contains the correct number of products, essential for maintaining quality control.
  
• Bundle Divert System: Actively diverts bundles that do not meet specified criteria (e.g., incorrect product count or mislabeling) for reprocessing, ensuring only conforming products proceed to final packaging.

• Hardy Check Weight Module: Provides a secondary verification to re-confirm the accuracy of each bundle’s weight, facilitating a final quality check before the products are cleared for dispatch.

• HMI10 Human Machine Interface: Offers a user-friendly interface for system control and monitoring, allowing operators to make real-time adjustments and respond to system alerts efficiently.

• Delta-X Real-Time Data Controller: Governs the entire system, providing advanced data traceability, integrity reporting, mix-up prevention, predictive analytics, and maintenance scheduling. This technology ensures high operational reliability and repeatability in product setups.

• Tamper-evident package security with hybrid adhesive seal and extended compression
• Batching, flow-wrapping, bundle labeling, and case and pallet manifest
• Automatic reissue of rejected cards, packs or bundles and on-the-fly bundle remake system

• Real-time data matching, tracking, validation and end-to-end reporting
• Virtual machine platform and system diagnostics
• 100% servo driven with digital brushless servo motors

• Inline card personalization, carrier affixing, secure packaging and pack-out speeds up to 20,000 PPH
• Duplex card personalization speeds up to 35,000 PPH
• Drop-on-demand UV printing at 600 DPI (3.5 pL drop size)

• Edge-to-edge affixing accuracy of ±0.5 mm in portrait and landscape orientation
• Labor: 1 operator + 2 person reloading + 1–2 people on delivery

• DOD inkjet printing: High-resolution drop-on-demand variable printing with 600 DPI at speeds up to 500 ft/min. Field replaceable Piezo print head with 3.5 pL drop volume and 75 mm print width (1D & 2D barcode, SIM ICCID, redemption code, card numbers, logos and graphics).
  
• Labelling: Apply all varieties of pressure-sensitive labels at line speeds up to 660 ft/min (400 labels per minute) and placement accuracy of ±0.4 mm (scratch-off, activation, magnetic stripe, RFID tag application). Minimize reloading frequency and increase productivity with up to 560 mm roll diameter.
  
• Magstripe encoding: Reverse, condensed, JIS encoding, with Hi-Co/Lo-Co coercivity selection at speeds of 35,000 cards per hour. Head lifespan over 100 million cycles.
  
• UV Curing: Single pass curing with high-powered LED UV lamp. Achieve an 85% increase in energy efficiency compared to standard arc or microwave technologies.

• Plasma treatment: Rapidly micro cleaning card surfaces and raising surface energy to improve wettability and adhesion of glue, inks, and coatings. Adjustable maximum power of 500 W with 50 mm performance width.
  
• Dual-belt vacuum transport: Independent personalization belts for ease of cleaning and prevention of premature cracking.
  
• Turnover and re-registration: Inline duplex personalization for improved productivity with modular design for quick changeover to straight-through card transport.
  
• Barcode grading: Ensures the production of high-quality products through verification of scan ability and compliance with barcode verification standards. Instantly identify B and C grade barcodes to reduce defect rates and associated costs from wasted material. Ability to run the Personalization section offline.

• Fugitive glue: Attach card to carries with low tack glue dots for reduced consumable cost.
• PSA adhesive label: Attach the card to carriers with pressure-sensitive labels.
  
• Cold glue: Tamper evident seal is accomplished with fibre crosslinking cold glue, which replaces legacy pressure seal applications.
  
• Extended compression: Ensure glue is fully cured and performing at speeds 10x faster than legacy pressure seal technology.

• Edge-to-edge card affixing: Modular alignment technology allows transferring cards and attaching to carriers with ±0.020” accuracy.
  
• Folding in all directions: With flexible folding options, including front, back, and plow fold, accommodate any type of form packaging factor with quick changeover times.
  
• Carrier printing & personalization: Print an activation barcode inline or apply a magnetic stripe label and match the card activation data.

• Batching and bundling: File-controlled dynamic batching allows for predetermined sequential bundling
  
• Shrink or flow wrapping: With options for bundle packaging, ensure your end products meet the customer’s requirements
  

• Labelling: Track piece-level sequence and provide an aggregated label for downstream distribution
  
• Pallet manifest: Provide complete card-to-pallet aggregation reporting

General

• Save recipes for module configurations to improve changeover and setup time
• Multi-level customizable user access for every single functionality of the software
• Data logger to create report files for details of every product exiting the final conveyor
• Define limit for sequential errors on sensors/data acquisition units checking the product status; the tracking system will trigger a fault when the maximum allowed consecutive errors occur

Data Integrity

• Match data between perso line and affixing line cameras to ensure accurate sequential product feed
• Log acquired data to a database file or verify the accuracy of scanned data by comparison to a database file
• Connect with centralized camera control unit for shared interface and communication with all cameras
• Tag non-conforming products after data matching or QC inspection for signalling to downstream modules Reproduction
• Generate a remake database for remaking diverted products while in production (on-the-fly reproduction) or after the current job has finished (end-of-job reproduction)

Batching

• Control batching rules for conditional batching based on tagged or remade products
• Track and signal divert for compensating batch counts
• Integration with relational databases (SQL, MySQL, Oracle, etc.) or ERP

Data Mapping & Integration

• Integration with relational databases (SQL, MySQL, Oracle, etc.) or ERP
• Tracking engine transmits print information to inkjet for printing 1D/2D barcodes, alphanumeric, counters, and more with multi-language support

Product Registration

• Sequential production by assigning the first record of the source database to the product passing through the registration sensor
• Dynamic production by mapping data from the data acquisition module to the source database
• Synchronize products as they move down the production line with product reregistration sensors on each belt for precise printing, reading, and tracking

• High-Speed Production: Capable of achieving speeds up to 13,000 UPH, optimizing production timelines.
  
• Precision Placement: Offers card and component placement accuracy of ±0.02″, ensuring each product meets the highest quality standards.
  
• Integrated Verification Systems: Built-in systems that track products throughout the production process, ensuring all errors are identified, diverted, and addressed.
  
• Virtual Machine Platform: 100% servo-driven system that provides unmatched reliability and flexibility.
  
• Multiple Component Inserting: Capability to insert various components seamlessly.

• Full Data Capturing and Reporting: Comprehensive system that tracks product data, provides insights, and generates detailed reports on any issues, allowing for real-time adjustments.
  
• Modular Design: A building block approach that allows customers to tailor the system to their specific needs, both at the time of purchase and in the future.
  
• End-to-End Solutions: Comprehensive solutions that cover everything from batching to wrapping and labelling bundles.
  
• Package and Component Personalization: Offers in-line personalization of cards, carriers, and more in a single system pass.

• Speed: Up to 13,000 UPH
  
• Placement Accuracy: Card and component placement accuracy of ±0.02″
  
• Personalization: 300–600 DPI DOD printing
  
• Recipe Storage: 20 recipes with additional storage available
  
• System Width: 38″
  
• System Length: 535.5″

• System Drive: 100% servo-driven with digital brushless servo motors
  
• Uptime: Upwards of 95%
  
• Minimum Material Size (Width × Length × Thickness): 1.25″ × 1.25″ × 0.01″
  
• Maximum Material Size: 9″ × 20″ × 0.17″
  
• System Height: 69.5″
  
• Card Material: Metal cards, Plastic cards, Paper / fiber-based cards, Composite cards, Premium specialty cards, Carbon fiber cards, Wood cards, Ceramic cards

• Rotary Pick & Place with Realignment: Employs vacuum pressure for precise card and carrier placement, managed by software for optimal alignment accuracy. Can feed metal cards.
  
• Vacuum Transport: Ensures smooth and stable transport, with software monitoring speed and stability to prevent misalignments.

• Smart Feeder: Feeds cards and carriers into the system, with software adjustments allowing for variations in material handling.

• DOD Inkjet and UV Drying: Delivers high-resolution printing with UV curing, software-controlled for precise ink deposition and curing times.
  
• Magstripe Encoder: Encodes magnetic stripes, with software ensuring correct encoding settings and verifying stripe quality.

• Camera Verification System: Uses Optical Character Recognition (OCR) to check print and encode quality, with software directing automatic corrections.

• Hot Melt Glue Application: Applies adhesive under software control to ensure consistent glue patterns and volumes.
  
• Plowfold: Mechanically folds the carrier, with software timing the folds to match the throughput speed.

• Front Fold and Bump & Turn: Additional folds and reorientation are tightly controlled by software to maintain precise alignment and packaging integrity.

• Scratch-Off Label Application: Software schedules and controls the application of scratch-off labels, integrating security features as required.
  
• Print and Apply Labelling: Final labeling is controlled by software, ensuring labels are accurately placed and contain correct information.

• Operator Interface with 15″ Screen: Provides a central hub for operators to interact with the system’s software, offering real-time diagnostics, adjustments, and feedback on system performance.

Delta-X Real-Time Controller

• System Oversight and Data Traceability: The advanced Delta-X controller manages all operational parameters, maintaining data integrity and traceability across the process. It supports predictive analytics for maintenance, on-the-fly adjustments for product setups, and detailed reporting for quality assurance.