• 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.

• Advanced UV Digital Printing: Utilizes state-of-the-art UV ink technology that adheres to any surface, including non-porous materials, ensuring versatile application across different substrates.
  
• High-Resolution Printing: Offers a maximum resolution of 600 DPI, providing fine detail and sharp images, ideal for complex graphics and high-quality labeling requirements.
  
• Full Web Print Area: Features a full 14.3-inch print width, allowing for large format printing and efficient use of media, reducing waste and increasing productivity.

• Extremely Low Ink Consumption: Designed for efficiency, the system uses UV ink sparingly without compromising print quality, significantly lowering operating costs over time.
  
• Integrated Inspection System: Equipped with a high-resolution line scan camera that continuously inspects the print for defects, ensuring only the highest quality products are produced.
  
• Real-Time Tracking and Defect Management: Incorporates the Delta-X Tracker system, which monitors every aspect of the printing process, automatically detecting and flagging or removing defects to maintain uninterrupted production flow.

• Vertical Resolution of 600 DPI: The vertical resolution of 600 dots per inch (DPI) ensures exceptionally detailed and sharp image quality. This high resolution is ideal for producing intricate graphics and precise text, critical for applications requiring high-quality print outputs such as detailed labels and flexible packaging.
  
• Horizontal Resolution of 300, 600, 900, and 1200 DPI: The WP-360 offers variable horizontal resolutions ranging from 300 to 1200 DPI. This flexibility allows the system to adapt to various print quality requirements, providing versatility in print detail and speed optimization. Higher resolutions are used for premium-quality prints, while lower settings can be selected to increase printing speeds without significantly compromising quality.
  
• Head Width of 365 mm: The print head width of 365 mm (approximately 14.37 inches) supports a broad print area, enabling the WP-360 to handle larger formats and wider web widths. This wide print head is particularly beneficial for full-web printing applications, allowing simultaneous multiple-lane printing, which maximizes productivity and material usage.

• Maximum Speed of 500 ft/min at 600 DPI: The WP-360 is capable of printing at speeds up to 500 feet per minute while maintaining a resolution of 600 DPI. This high-speed capability ensures rapid production cycles, making it suitable for high-volume industrial environments where both speed and print quality are essential.
  
• Drop Volume of 3.5 pL: With a minimal drop volume of 3.5 picoliters (pL), the WP-360 achieves an excellent balance of print clarity and ink efficiency. The small drop size allows for fine detail and smooth gradations in images while also reducing ink consumption, which is crucial for maintaining lower operational costs in large-scale production.
  
• Ink Delivery System: The WP-360 offers two ink delivery system options: gravity-fed and recirculating. Gravity-fed systems are straightforward and cost-effective, suitable for simpler applications. In contrast, recirculating systems help maintain ink viscosity and temperature consistency, which is beneficial for longer runs and varying environmental conditions, ensuring consistent print quality throughout the production process.

• SJ365 Wide-Format Smart Jet: Handles large-format UV digital printing across the full web width of 14.3 inches. The system’s advanced print head technology ensures high-resolution output at 600 DPI, suitable for detailed and complex graphics.

• UV Curing System: Integrates directly after the printing module to instantly cure the ink, making it adhere to various substrates and ensuring durability and quality of the print, regardless of material porosity.

• VS1000 Vision Scan Camera: Employs a high-resolution line scan technology to inspect the web width thoroughly. It checks for print quality, alignment, and any defects in real-time, utilizing advanced image processing algorithms.

• Defect detection and management: Identifies any inconsistencies or quality issues within the print. The system tags defects for removal or flags them for review, ensuring that only products meeting quality standards proceed to the next stage.

• Automated labeling and packaging: Post-inspection, products that meet the quality standards are forwarded to the labeling and packaging stages. This part of the workflow involves automated systems that apply necessary labels and prepare the products for shipping.

• Quality assurance reporting: The Delta-X software compiles comprehensive reports on product quality, defect rates, and system performance, providing valuable insights for continuous process improvement.

• Delta-X Tracker: Serves as the central control software for the WP-360 system. It manages data tracking and integrity across the printing process, providing predictive analytics, maintenance alerts, and repeatable product setups. This software ensures that every part of the print process is monitored and optimized for quality and efficiency.

• Integration with Existing Line Equipment: Seamlessly connects with other in-line systems such as roll splicing, foil stamping, and RFID tagging. This integration allows for a unified operation where all processes are controlled via the Delta-X interface, enhancing operational coherence and reducing the need for multiple control points.

• 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.

• Modular System Approach: Enables simultaneous execution of various in-line processes such as folding, gluing, creasing, tipping, Braille embossing, and digital imaging. 
  
• Multiple Delivery Options: Offers choices like shingled, in batches, or bridging modules for diverse delivery needs. 
  
• Networked Brushless Servo-Driven Technology: Ensures timely and efficient feeding of blanks. 
  
• Speed Compensation: Provides consistent speed adjustments for all cylinders. 
  
• Recipe Functionality: Allows for the storage of jobs and machine parameters with extensive diagnostics for quick setups. 

• Connectivity Features: Equipped with Ethernet and internet connectivity via a laptop for real-time monitoring and control. 
  
• Durable Construction: Built with Stainless Steel Planetary gearheads for longevity. 
  
• Advanced Control Systems: Utilizes a fiber-optic networked control system for fast communication and real-time adjustments. 
  
• Variable Speed Delivery System: Ensures optimal output by adjusting the system’s speed based on product requirements. 
  
• High-Speed Belt Lifting: Features automatic speed compensation for consistent product handling. 

• Affixing accuracy of ±0.5 mm
  
• Maximum carton speed up to 30,000 cartons per hour
  
• Networked brushless servo driven

• Fiber-optic networked
  
• Variable speed with batching
  
• High-speed with automatic speed compensation

• Smart Feeder: Efficiently automates your document inserting processes with speed and ease. Tasks combining multiple pre-fold inserts/outserts in variable stack counts are accomplished with the utmost precision and productivity, providing a quicker return on investment. 
  
• Vacuum Conveyor: High torque servo-driven vacuum transport conveys products at exacting speeds and controls product placement with 8 selectable vacuum zones.  

• Delivery Transport: The delivery conveyor is designed with several ergonomic features minimizing fatigue of the operator when handling products in high-speed applications.

• Barcode Scanning Module: ISO Grading and/or data capturing virtualy all types of linear 2D barcode.  Any non-conforming products are automatically diverted to ensure maximum throughput.

• High-Speed Label Applicator: A highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications. 

• Divert Gate: Divert non-compliant products from the product stream through a reciprocating gate. 

• 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 Performance

• Industry-leading speeds of up to 30,000 PPH
• Optimized end-to-end solutions, including batching, wrapping, and labelling bundles

Integrated Verification Systems

• Consistent quality checks throughout the production process
• Automated error detection and diversion to ensure product accuracy
• Remake initiation for guaranteed 100% verified products

Comprehensive Software & Hardware Platform

• Powered by Pack-Smart Inc.’s robust virtual machine software/hardware platform
• Rugged fiber-optic network ensures reliable data transfer and processing
• Customizable report compliance interface for tailored data insights

Versatile Card Handling

• Efficient management of diverse card formats, including CR80s, M6 hang tags, and custom-shaped cards
• Personalization features such as magstripe label affixing, 1D and 2D barcode printing, and scratch-off label application

Modular & Adaptable Design

• Tailored solutions to meet specific production needs
• Future-proof design allows for system customization and integration of new features

• Speed: Up to 30,000 UPH
• Personalization: Magstripe label affixing, 1D and 2D barcode printing, scratch-off label application

• Card Formats Supported: CR80s, M6 hang tags, and many custom-shaped cards
• Verification: Integrated systems for product tracking and error detection

• Feeding, Registration and Alignment: Rotary Pick and Place Feeder consistently feeds, inserts, attaches, and batches delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
  
• Smart Chip Encoding: Pack-Smart’s SCE-1 Smart Card Encoding module is designed to provide a versatile drop-in enhancement for CP-250 systems to benefit from expanded EMV and contact/contactless card encoding capabilities. The high-speed encode module combined with pogo pin contact interface allows easy integration with customers’ existing infrastructure and provides a solid return on investment. 
  
• Magnetic Strip Encoding: High-speed and modular magnetic encoding solution designed with advanced and industrial-grade electronics and integrated magnetic stripe encoding software. Module supports encoding magnetic stripes from top and bottom. System can be configured with two or three-track read and write heads, providing reliable magnetic stripe encoding capabilities. Card personalization of products of any size and shape in compliance with ISO standards.

• DOD Variable Print: Smart Jet uses industry-leading head technology to deliver UV-cured 600 DPI DOD Ink onto any surface at speeds over 500 feet per minute. Up to 8 heads can be combined to reach widths of 575 mm for full web or press sheet personalization.
  
• UV Drying: The UVL features a high-power LED UV lamp intended for high-speed, single-pass drying or curing applications. The air-cooled LED lamp allows for an 85% increase in energy consumption as compared to traditional, long lifecycle, easy setup, and minimal maintenance for a high-efficiency process compared to typical arc or microwave technologies. The UVL reduces wear on conveyor belts and enables compatibility with heat-sensitive substrates.

• Label Application: High-Speed Label Applicator is an asset in any demanding manufacturing environment. With the ability to apply all varieties of pressure-sensitive labels at line speeds up to 200 m/min (660 ft/min), the HSL-60 can apply 400 labels per minute, with a best-in-class placement accuracy of ±0.4 mm. Depending on material and label size, Pack-Smart HSL-60 Labeller will accurately apply labels to any product in line with any printing, converting and packaging production lines. When operating in a “Zero Downtime“ configuration, the HSL-60 tandem system allows for safe “on the fly” roll changes eliminating downtime required for roll changes.

• Inspection, Verification & Placement Inspection: Area Scan Vision will inspect variable OCR, barcode, and ANSI verification, as well as perform print and placement quality checks. The native 64-bit environment alongside the Xenon processors allows image processing as fast as 120 FPS.

• Divert & Rejection: The DV Series Divert Modules are responsible for removing non-conforming products from the production line. High-speed ejecting cylinders governed by Data Tracking and Machine Logic controllers are activated in real time to ensure 100% conforming products are delivered. Fail safe sensors track product rejection to ensure assumption free operation.

• Product Delivery: The delivery conveyor is designed with several ergonomic features minimizing fatigue of the operator when handling products in high-speed applications. Two stage height adjustment on each end of the conveyor allows for quick adjustment of table elevation, based on operator preference. Variable speed with batching ability provides gaps eliminating needs for counting finished product, while increasing productivity. Four-inch locking casters are a standard feature of DL 500 providing outstanding mobility.

• 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 the limit for sequential errors on sensors/data acquisition units checking the product status. The tracking system will trigger a fault when a maximum allowed consecutive errors occur.