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.
HSS-10
High-Speed
Automated Mail
Sorting System
Mailpiece identity has to remain connected to the routing decision. The HSS-10 feeds, stabilizes, reads and sorts barcode-identified envelopes across ten shingled delivery outputs while Delta-X Trust provides live production status, exception visibility and event-level control.
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 batch or released without a clear production record.
The HSS-10 automated mail sorting system connects envelope feeding, vacuum transfer, barcode reading, destination lookup, divert control and shingled accumulation in one coordinated workflow. Each recognized barcode drives a defined routing decision. Unreadable or unrecognized mailpieces are contained through configured exception logic rather than being silently released into an incorrect output.
-
Secure Card and PIN Mailers
-
Government and Citizen Communications
-
Healthcare Member Communications
-
Loyalty and Promotional Mailers
Automated Mailpiece Routing
- Barcode-driven destination lookup
- Ten configured sorting destinations
- Stable transfer through identification & sort
- Shingled output for downstream handling
Exception Containment
- Detection of unreadable or unrecognized barcodes
- Defined routing for unresolved mailpieces
- Separation of exceptions from valid outputs
- Clear rejection reasons for user response
Live Production Awareness
- Delta-X Trust system and job status
- Real-time speed and production progress
- Production statistics and event visibility
- Stronger traceability from identification through sorting
Watch the High-speed Automated Mail
Sorting System in Action
The video also shows the Delta-X production-awareness interface monitoring the sorter, destination layout,
current operating status, production progress, rejection reasons and system events.
- Controlled Envelope Feeding: The SF500 feeder presents flat mailpieces individually to support consistent entry into the identification and sorting process.
- Vacuum-Assisted Transfer: The VC500-6 transfer module stabilizes the mailpiece as it moves from feeding into the scanning section.
- Inline Barcode Reading: The BSC1000 scanning module reads the unique barcode used to identify the mailpiece and initiate the routing decision.
- Data-Driven Destination Lookup: The system resolves the barcode against configured job data to determine the appropriate sorting destination.
- Exception Handling: Unreadable or unrecognized barcodes can be flagged and directed according to defined reject or exception rules.
- Ten-Pocket Sortation: Ten DV250 divert modules route recognized mailpieces to their assigned destinations.
- Shingled Delivery: Ten DL500 delivery conveyors accumulate sorted mailpieces in an organized shingled arrangement.
- 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 the feeding, transfer, scanning and divert sequence.
- 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
[VERIFY]
- Demonstrated speed: Delta-X display reaches 9,000 PPH in the attached video
- Identification method: Unique barcode reading
- Routing method: Destination lookup based on barcode value
- Exception condition: Unreadable or unrecognized barcode
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: The SF500 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: The VC500-6 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: The BSC1000 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: The BR900 moves the identified mailpiece into the sorting section.
- Controlled diversion: A DV250 divert module directs the mailpiece toward its assigned destination.
- Ten sort destinations: The configured system separates mailpieces across ten defined outputs.
- Shingled accumulation: DL500 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.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
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.
DL Series
Shingled Delivery Transport
Discover the DL Series Shingled Delivery Transport, designed for efficient and ergonomic conveying of diverse printed materials.
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.
-
Fast Moving Consumer Goods
-
Pharmaceutical Products
-
Open Loop Cards
-
Closed Loop Cards
-
Membership & Loyalty
-
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.
MD-200
Multi-Stream
Finishing and
Packaging System
Elevate your medical kit production with the MD-200, a multi-stream finishing & packaging system engineered for high efficiency and precision in assembling and packaging medical-grade antigen test kits.
High-Speed Medical Kit Finishing with Multi-Stream Production Control
The MD-200 Multi-Stream Medical Kit Finishing and Packaging System is designed for high-volume medical kit production where component placement, serialization, folding, and wrapping must stay synchronized across multiple production lanes.
Built for rapid antigen tests, diagnostic kits, and medical-grade packaging workflows, the MD-200 adds kit components, folds the carrier, applies DOD serialization, and guides each finished kit into the wrapper without interrupting production flow. Servo-based motion control, quick roll changeovers, and configurable lane architecture help manufacturers improve throughput while maintaining repeatable kit assembly and packaging integrity.
Medical Kits
Pharmaceutical Products
Fast Moving Consumer Goods
Efficiency
- Multiple-stream technology supports simultaneous kit assembly.
- Achieves a production speed of 200 PPM, optimizing throughput.
- Quick changeover capabilities minimize downtime between production runs.
Precision
- Advanced servo-driven system ensures precise component placement.
- DOD serialization for accurate tracking and compliance.
- Real-time data tracking and validation enhance product integrity.
Cost-Effectiveness
- Reduces labor costs with automated multi-lane processing.
- Lowers per-unit production costs through efficient design and operation.
- Minimizes waste with precise material handling and usage.
Watch the Multi-Stream Finishing and Packaging
System in Action
- Multi-Lane Configuration: Simultaneously assembles multiple kits, increasing throughput.
- Integrated DOD Inkjet Printing: Offers high-resolution serialization directly on components, enhancing traceability.
- Automated Quality Control: Utilizes advanced sensors and cameras to ensure each kit meets exact specifications.
- Servo-Driven Precision: Features digital brushless servo motors for precise motion control throughout the assembly process.
- Real-Time Data Monitoring: Incorporates a system for instant data tracking and validation to ensure production accuracy.
- Advanced User Interface: Equipped with a sophisticated HMI (Human Machine Interface), enabling easy control and monitoring of the system.
- Throughput Capacity: Capable of handling up to 200 kits per minute, optimizing production efficiency.
- Quick Changeover: System design allows for rapid adjustments, with changeovers taking just 2–3 minutes.
- Serialization Technology: Utilizes Drop-on-Demand (DOD) inkjet printing at 600 DPI for detailed and durable markings.
- Material Handling: Designed to work with a variety of packaging materials, including sensitive medical components.
- Operational Dimensions: Accommodates multiple lanes with adjustable settings to handle different kit sizes and configurations.
- Compliance and Safety: Meets high standards for medical device production, ensuring compliance with regulatory requirements.
Process Flow
From Component Loading to Wrapped Medical Kit Output
The MD-200 Metal Detector plays a crucial role in the quality assurance process by integrating seamlessly into the production line to detect metallic contaminants. Products pass through the detector, where high-sensitivity sensors scan for any metal fragments. Upon detection, the system signals the rejection mechanism, promptly removing the contaminated product from the line.
- Single-Stream Buffer Transport Module: Manages the flow from upstream assembly to maintain continuous production without bottlenecks.
- RP300 Rotary Pick and Place Feeder: Accurately places components into the system with high precision, preparing them for wrapping and sealing.
- E10 Wrapper with 4-Side Seal: Ensures each medical kit is securely sealed, maintaining product integrity and sterility with precise four-side sealing.
- DF400 Desiccant Feeder with Bulk Unwind Station: Integrates desiccants into the packaging, cut and dispensed synchronously with the packaging speed.
- SJ75 DOD Inkjet System with Controller: Applies high-resolution UDI codes and other critical information directly onto the packaging film.
- DV250 Divert Module: Diverts any non-conforming kits out of the production line, ensuring only products that meet quality standards proceed.
- VSC1000 Vision Scan Camera: Inspects all print work for accuracy, clarity, and placement, ensuring compliance with quality standards.
- HMI10 Human Machine Interface and Allen-Bradley System Motion Control: Provides central control and monitoring of the entire system, allowing adjustments and real-time tracking.
- Delta-X Tracker Real-Time Data Controller: Offers end-to-end data traceability, tracking critical data for compliance and production efficiency.
Included Technologies
The MD-200 leverages Delta-X software for real-time control and end-to-end reporting, ensuring precision in medical kit assembly. Its servo-driven mechanisms enhance placement accuracy and speed, while its seamless integration with high-speed DOD printing meets stringent regulatory demands, significantly boosting throughput with minimal downtime.
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.
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.
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.