VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
HSS-10
High-Speed
Automated Mail
Sorting System
Mailpiece identity has to remain connected to the routing decision. The HSS-10 feeds, stabilizes, identifies, and sorts barcode-driven flat mailpieces across ten shingled delivery outputs. Delta-X Trust provides live job status, production tracking, exception visibility, and system-event information throughout the sorting workflow.
Controlled Mail Routing Before Dispatch
Final sorting is not simply a material-handling step. For personalized or sensitive communications, it is one of the last points where a correctly produced mailpiece can still be routed to the wrong destination, mixed into the wrong output, or released without clear production visibility.
The HSS-10 automated mail sorting system connects controlled feeding, vacuum-assisted transport, barcode reading, job-data lookup, divert control, and shingled delivery in one coordinated workflow.
Each identifier is resolved against active job data before the mailpiece is assigned to a destination, while unreadable codes and records without a valid match trigger configured exception logic. By integrating the mechanical, sensing, motion-control, operator-interface, and production-tracking components as one configured system, this creates a controlled handoff from personalized production to downstream collection, batching, or dispatch.
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Secure Card and PIN Mailers
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Government and Citizen Communications
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Healthcare Member Communications
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Loyalty and Promotional Mailers
Controlled Mailpiece Routing
- Barcode-driven lookup against active job data
- Ten configured sorting destinations
- Vacuum-assisted transfer through identification and sortation
- Shingled output for controlled downstream handling
Exception Containment
- Detection of unreadable or unrecognized barcodes
- Configured handling of unresolved mailpieces
- Separation of valid routing decisions from exceptions
- Visible exception reasons for operator response
Live Production Awareness
- Delta-X Trust system and job status
- Real-time speed and production progress
- Production statistics and event visibility
- Line-level visibility from identification through sortation
Watch the High-speed Automated Mail
Sorting System in Action
Watch flat mailpieces being separated and introduced into the transport path, stabilized through the identification stage,
resolved against destination data, and directed across ten shingled delivery outputs.
- Controlled Envelope Feeding: feeder separates and presents approved flat mailpieces individually to support consistent entry into the identification and sorting process.
- Vacuum-Assisted Transfer: transfer module stabilizes each mailpiece as it moves from feeding into the code-reading and data-capture area.
- Inline Barcode Reading: captures the unique linear barcode used to identify the mailpiece and initiate the destination-lookup process.
- Configurable Vision and OCR Capture: capture 2D Data Matrix codes and selected OCR fields in addition to linear barcode data.
- Data-Driven Destination Lookup: the captured identifier is compared with the active job data to determine the mailpiece’s assigned sorting destination.
- Configured Exception Handling: Unreadable codes and identifiers without a valid destination match are flagged and handled according to the approved exception rules.
- Ten-Destination Sortation: executes the routing decision and direct recognized mailpieces toward their assigned outputs.
- Delta-X Trust Production Awareness: Delta-X Trust connects system status, production events, rejection information and job progress to the operator interface.
- Configurable Motion Control: The Emerald 2500 controller coordinates feeding, transfer, identification, divert timing, and delivery across the configured system.
- Operator Interface: The HMI10 provides access to system operation, job awareness, diagnostics and production information.
- System type: Barcode-driven envelope and flat-mailpiece sorting system
- Sort destinations: 10 pockets
- Documented media: #10 envelopes and folded flat packages
- Rated throughput: 10,000+ mailpieces per hour
Process Flow
The HSS-10 controls the complete mail-sorting workflow, from envelope feeding and barcode identification to destination-controlled diversion, shingled delivery, and production tracking. Each stage keeps the physical mailpiece connected to its routing data so recognized items reach their assigned outputs and unresolved pieces remain visible for operator action.
The mailpiece preparation stage separates and stabilizes each envelope before identification. This establishes the controlled position and transport conditions
required for consistent barcode reading and downstream routing.
- Envelope feeding: Introduces #10 envelopes or approved flat mailpieces into the transport sequence.
- Individual presentation: Mailpieces are separated and presented individually for controlled downstream processing.
- Vacuum stabilization: Maintains control of each mailpiece as it moves toward the barcode-reading station.
- Scan-path entry: The transport sequence positions the mailpiece for stable presentation through the identification area.
The identification stage connects each physical mailpiece to its active job data. The captured barcode is resolved against the configured destination rules
before the piece enters the sorting section.
- Barcode reading: Captures the unique barcode associated with the mailpiece.
- Job-data lookup: The captured value is compared with the active production data.
- Destination assignment: A recognized record is converted into a routing instruction for the appropriate sort destination.
- Unreadable-code handling: A barcode that cannot be captured is flagged according to the configured exception logic.
- Unrecognized-record handling: A readable code without a valid destination match remains visible for operator response.
The sortation stage executes the routing decision across ten configured destinations. Each validated mailpiece is transferred, diverted, and
accumulated for controlled removal and downstream handling.
- Bridge transfer: Moves the identified mailpiece into the sorting section.
- Controlled diversion: Divert module directs the mailpiece toward its assigned destination.
- Ten sort destinations: The configured system separates mailpieces across ten defined outputs.
- Shingled accumulation: Delivery conveyors organize sorted mailpieces in a controlled shingled arrangement.
- Output handling: Completed groups remain accessible for removal, counting, batching, or the next production step.
The software and control stage coordinates system movement, routing execution, production status, and exception visibility. Operators can monitor
the active job without separating mechanical activity from the data governing each decision.
- Delta-X Trust tracking: Connects job progress, production activity, and mailpiece-routing events.
- Operator interface: The HMI10 provides access to system status, operating controls, and diagnostic information.
- Motion coordination: The Emerald 2500 coordinates feeding, transfer, identification, diversion, and delivery.
- Production monitoring: Operators can view running status, production speed, job progress, and production statistics.
- Exception visibility: Rejection reasons and system events help operators identify where intervention is required.
Included Technologies
The HSS-10 combines feeding, vacuum transport, barcode reading, motion control, ten-pocket sortation, shingled delivery and Delta-X Trust
production tracking into one configured system.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
DZ Series
Zoned Divert Gate System
Elevate efficiency with the DZ Series Zoned Divert, designed for precise sorting and high-capacity handling in demanding industrial environments.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
BA-250
High-Speed Automated
Pack-Out and Fulfillment
System
Maximize efficiency with the BA-250, a fully automated pack-out and fulfillment system designed for wrapping, inline batching, bundling, and labeling, enhancing throughput up to 2,000 bundles per hour.
Revolutionize Pack-Out with Precision Automation
The BA-250 Automated Pack-Out and Fulfillment System is Pack-Smart’s state-of-the-art solution for inline batching, wrapping, and aggregate labeling, delivering up to 2,000 finished bundles per hour with precision and reliability.
This advanced system seamlessly integrates key functions, including batching, wrapping, scanning, weighing, and quality assurance. Each bundle, case, and pallet is labeled with pinpoint accuracy, streamlining workflow efficiency and ensuring end-to-end traceability for high-demand production environments.
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Fast Moving Consumer Goods
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Pharmaceutical Products
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Open Loop Cards
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Closed Loop Cards
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Membership & Loyalty
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Serialized Products
Streamlined Production
- Enhances on-time delivery with integrated packaging processes.
- Produces up to 2,000 bundles per hour, accelerating market readiness.
- Fully automated system reduces the need for manual intervention, lowering labor costs.
Quality Assurance
- Incorporates a QA station that rejects and remakes bad products on the fly.
- Ensures 100% product integrity and quality with advanced scanning and weighing technologies.
- Automated labeling system maintains accuracy and consistency across all bundles.
Advanced Integration
- Utilizes camera-based aggregation to ensure precise product grouping.
- Weight verification of each bundle confirms the correct number of products before packaging.
- Delta-X control system offers real-time data traceability and advanced reporting capabilities.
Watch the Pack-Out Fulfillment System in Action
- 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
Process Flow
The BA-250 exemplifies streamlined operational excellence, featuring a process flow that optimizes speed and precision. From material handling to the final inspection, each stage of the process is meticulously engineered to enhance productivity and ensure the highest quality output.
- 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.
Included Technologies
The BA-250 integrates a suite of cutting-edge technologies that elevate its operational capabilities. It incorporates advanced sensors for real-time monitoring, precision actuators for accurate material handling, and sophisticated software for seamless automation. These technologies work in harmony to ensure the BA-250 delivers exceptional performance, making it a robust solution for industries seeking to leverage technological advancements for improved efficiency and quality.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
BC Series
Batch Counter & Bundling
Efficiently batch single products into precise groups with Pack-Smart’s BC Series, designed for a wide range of materials and applications.
DZ Series
Zoned Divert Gate System
Elevate efficiency with the DZ Series Zoned Divert, designed for precise sorting and high-capacity handling in demanding industrial environments.
HSL-60
High-Speed Label Applicator
The HSL-60 is a highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
3DF-1
3D Product
Feeding System
Revolutionize your production line with the automated 3D Product Feeding System, designed to sort, orient, and affix loose 3D products with unparalleled speed and precision.
Advanced Automation for 3D Product Handling
3DF-1 uses a high speed vibratory bowl to handle delicate format 3D products. Once the parts are sorted and correctly oriented, they are transfered to a redundant set of buffers.
These buffered parts are then transfered to lugged horizontal track which allows smooth control of the products at the same time meeting the feeding request of the line. A precise rotary motion pick and place system will deliver them from the lugs to the packaging line.
Fast Moving Consumer Goods
Pharmaceutical Products
Reduce Manual Labor
- Eliminates the need for manual sorting and placement
- Decreases staffing requirements, reducing labor costs
- Enhances workplace safety by minimizing human interaction with machinery
High Throughput
- Handles up to 200 products per minute, maximizing productivity.
- Maintains consistent operation even under high-demand conditions.
- Reduces bottlenecks in the production line, ensuring a smooth flow.
Reliability & Precision
- Care-free bulk loading reduces downtime and increases operational reliability.
- Redundant feed channels ensure there is no interruption in the feeding process.
- Precision handling of 3D products prevents damage and improves quality control.
Watch the 3D Product Feeding System in Action
- High-speed vibratory bowl for efficient product sorting
- Dual buffering system to accommodate high throughput
- Advanced rotary pick and place system for precise product placement
- Vacuum-assisted horizontal tracks for smooth control and transfer
- Lugged horizontal track to maintain product orientation and spacing
- Integrated control system with HMI10 for easy operation
- Speed: Up to 200 3D products per minute
- Product Size Range: 10 × 10 mm to 50 × 50 mm
- Material Handling: Capable of processing various materials from lightweight to heavy stock
- Feed Method: Vacuum nests rotary head with fiber-optic sensing
- Power Requirements: 230 V AC, 3 phase, max 30 A
Process Flow
The 3DF-1 operates within a highly structured process flow designed to maximize both precision and efficiency in 3-dimensional product feeding. Starting with the automated feeding of items into the system, each component is carefully aligned and transported through various stages of handling and assembly.
- VF900 Vibratory Bowl Feeder: Sorts and aligns products for further processing.
- Vacuum Driven Horizontal Track: Transfers aligned products toward the placement station.
- 3D50 3D Object Feeder: Accurately picks and places products onto the next stage of the production line with precise control.
Included Technologies
Utilizes a high-speed vibratory bowl combined with a vacuum-assisted rotary head for precise product handling and placement. This system ensures gentle handling of 3D products, reducing waste and increasing efficiency. The integrated fiber-optic sensing guarantees exact product positioning, enhancing the overall precision of the production process.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
RPP Series
Reciprocating Pick and Place Series
Maximize your production efficiency with the RPP Series, designed for high-speed, accurate handling of delicate materials and uniquely shaped products.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
FG-800
Reinforced Carton
Specialty Finishing
System
Single-pass reinforced carton finishing system that combines folding, gluing, component affixing, personalization, and sorting for high-value and auto-erect cartons.
High-Speed Reinforced Carton Finishing with Quick Changeovers
The FG-800 Reinforced Carton Specialty Finishing System gives manufacturers the flexibility to produce high-value folding cartons, reinforced cartons, and auto-erect cartons in one configurable workflow. It combines carton registration, folding, gluing, component affixing, personalization, and sorting without moving work between separate finishing steps.
Built on a servo-driven platform with fiber-optic controls, the FG-800 supports quick make-readies, hot and cold glue application, rotary pick-and-place feeding, and flexible inline folding modules. This allows producers to run multi-substrate carton designs with speeds up to 10,000 PPH, carton widths up to 30 inches, and ±0.4 mm affixing accuracy.
High Value Carton
Auto-Erect Cartons
Advanced Flexibility & Precision
- State-of-the-Art Registration: Utilizes innovative servo technology for swift and effortless carton alignment.
- Versatile Folding Modules: Exceptionally flexible inline folding modules ensure quick make-readies for diverse carton packages.
- Accurate Affixing: High-speed Rotary Pick and Place Feeders for precise feeding and affixing of a wide range of materials, including corrugated, rigid, and uniquely shaped items.
- Affixing Accuracy: Achieves an impressive accuracy of ±0.4 mm.
Comprehensive Integration & Efficiency
- All-in-One Solution: Combines folding, gluing, affixing, personalization, and sorting capabilities in a single pass, enabling the creation of unique multi-substrate based folding cartons.
- Advanced Gluing Technology: Equipped with both hot and cold glue technology, installed with flexible mounting attachments for versatility within the gluer.
- High Throughput: Achieves speeds of up to 10,000 PPH with the capability to handle cartons up to 30″ in width.
Cutting-Edge Technology & Design
- Fiber Optic Network: Built on a state-of-the-art fibre optic network, ensuring seamless communication and operations.
- Brushless Servo-Technology: Employs advanced motion control for unparalleled production flexibility and throughput.
- Diverse Folding Capabilities: Offers front fold, back fold, plow fold, and auto-erect cartons, catering to high-value carton processing needs.
- Related Integration: Compatible with the RP Series, further expanding its capabilities.
Watch the Reinforced Carton Specialty
Finishing System in Action
- State-of-the-Art Registration Module: Employs innovative servo technology for precise carton alignment, ensuring consistent quality.
- Versatile Folding Capabilities: Equipped with inline folding modules that allow for front fold, back fold, plow fold, and auto-erect cartons, catering to a wide range of packaging needs.
- Advanced Gluing System: Incorporates both hot and cold glue technologies, adaptable within the gluer through flexible mounting attachments.
- Brushless Servo-Technology: Utilizes advanced motion control for unparalleled production flexibility and throughput.
- High-Speed Rotary Pick and Place Feeders: Designed for fast and accurate feeding and affixing of various materials, from corrugated to rigid and uniquely shaped items.
- Multi-Functional Capabilities: Combines folding, gluing, affixing, personalization, and sorting in a single pass, maximizing production efficiency.
- Fiber Optic Network Integration: Built on a state-of-the-art fiber optic network, ensuring seamless operations and communication between modules.
- Throughput: Up to 10,000 PPH
- Affixing Accuracy: ±0.4 mm, ensuring precise placement and adherence of materials
- Carton Width Capacity: Up to 30 inches
- Processed Material Types: Specializes in high-value carton and auto-erect cartons
- Gluing Technologies: Equipped with both hot and cold glue systems, adaptable for various packaging needs
- Related Compatibility: Seamlessly integrates with the RP Series for expanded capabilities
Interactive Process Flow
The process flow for the FG-800 Reinforced Carton Specialty Finishing System is designed to ensure precise, secure, and efficient production of folding cartons. This system integrates each step, from initial material feeding and registration to final gluing and finishing, ensuring high-speed, accurate application with robust security measures.
- Friction Feeder: The FG-800 utilizes the FF1500 Friction Feeder, which ensures consistent and reliable feeding of corrugated blanks into the system. This feeder is designed to handle a variety of materials, maintaining high speeds and precision.
- Registration Module: The registration module aligns the material positioning and spacing between incoming blanks, ensuring accurate processing throughout the production line.
- Friction Feeder: FF Series friction feeders are designed with a solid steel construction to ensure stability and high performance even in the toughest environments, resulting in high production speeds of up to 600 PPH.
- Hot Glue System: The HM10 Hot Melt Secure Glue System applies hot glue for tamper-resistant and secure enclosure gluing. This system ensures a strong bond that is essential for high-security applications.
- Rotary Pick and Place Feeder: Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
- Cold Glue System: The CEG1 Cold Extruded Glue System applies cold glue, providing a tamper-evident seal. This system is ideal for applications requiring high levels of security and precision.
- Plow Fold Module: The PF50-90 Plow Fold Module can fold sheets and booklets at high speeds, accommodating both left and right folds. It is versatile, allowing for tool-less adjustments to meet various folding requirements.
- Vacuum Transport: The VC1500-12 Vacuum Transport module provides smooth and efficient variable speed transport for the host blanks, ensuring that materials move through the system without disruption.
- Front Fold Module: The MFF120 Front Fold Module ensures precise folding of materials, using air jets and hooked arms to achieve accurate folds. This module is essential for creating high-quality finished products.
- Extended Compression: This feature ensures that the glue is fully cured at speeds 10 times faster than legacy pressure seal technology, enhancing the strength and durability of the final product.
- Delta-X Data Management Platform: The Delta-X software provides real-time tracking, configurable workflows, and batch processing. This system ensures that all production data is accurately tracked and managed, enhancing overall operational efficiency.
- HMI-10 Interface: The HMI-10 graphic interface connects operators with the machine, combining a PLC and HMI into one unit. This interface offers intuitive controls and real-time data, facilitating easy operation and management of the FG-800 system.
Included Technologies
The FG-800 Reinforced Carton Specialty Finishing System incorporates advanced technologies to enhance its performance and reliability. Key technologies include high-speed friction feeders, precision affixing mechanisms, advanced folding modules, and real-time data management systems. These technologies work together to ensure consistent, high-quality production of folding cartons.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
FF Series
Primary Friction Feeder
The FF Series Friction Feeder can handle the lightest paper and is equally at home when dealing with heavy stock materials when called upon.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
HSL-60
High-Speed Label Applicator
The HSL-60 is a highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications.
SF Series
Secondary Friction Feeder
Reaching up to 600 products per minute, the SF Series is a perfect choice for handling light paper to heavy stock material.