BA-250

Maximize efficiency with the BA-250, a fully automated pack-out solution designed for inline batching, bundling, and labeling, enhancing throughput up to 2,000 bundles per hour.

Camera-Based
Aggregation

Bundle Verified
by Weight

Automated
Bundle Labeling

The BA-250 is Pack-Smart’s advanced solution for inline batching, wrapping, and aggregate labeling, capable of handling up to 2,000 finished bundles per hour.

This system integrates functions such as batching, wrapping, scanning, weighing, and quality assurance, with each bundle case and pallet labeled accurately, ensuring optimal workflow efficiency.

  • Fast Moving Consumer Goods

  • Pharmaceutical Products

  • Open Loop Cards

  • Closed Loop Cards

  • Membership & Loyalty

  • Serialized Products

  • 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.
  • 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.
  • 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.
 
  • 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

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.

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 VSC1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.

3DF-1

Revolutionize your production line with the 3DF-1, designed to sort, orient, and affix loose 3D products with unparalleled speed and precision.

Care-Free Bulk Loading

Redundant Feed Channels

Up to 200 3D PPM

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

  • Eliminates the need for manual sorting and placement
  • Decreases staffing requirements, reducing labor costs
  • Enhances workplace safety by minimizing human interaction with machinery
  • 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.
  • 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.
 
  • 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

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.

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

Combine folding, gluing, affixing, personalization, and sorting in a single pass.

10,000

Products per Hour

Up to 30″

Carton Width

±0.4 mm

Affixing Accuracy

100%

Servo-Driven Platform

7″

Color HMI

The FG-800 is designed to give the tools and flexibility needed to explore new manufacturing opportunities in the folding carton and specialty finishing world. The alignment of cartons is handled by a state-of-the-art registration module, which employs innovative servo technology making setups swift and effortless.

High Value Carton

Auto-Erect Cartons

  • 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.
  • 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.
  • 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.
 
  • 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

The process flow for the FG-800 Rigid Window Affixing 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.

The FG-800 Rigid Window Affixing 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

Friction Feeder

Worlds first inline solution for high volume personalization, affixing, packaging and pack-out of secure open and closed loop cards at 20,000 PPH.

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.