AL Series
Powered Autoloader
Maximize productivity with the AL Series Powered Autoloader. Designed to extend loading capacities and reduce manual reloading for high-speed applications, ensuring continuous operation and efficiency.
TF-500
Tray Forming and
Fulfillment System
Delivers unmatched automation, producing 3,500+ products per hour while ensuring 100% product integrity. Designed for scalability, accuracy, and seamless integration, this state-of-the-art system will transform your packaging operations with modular flexibility.
Next-Generation Tray Forming & Filling — Precision, Speed, and Flexibility
In industries where presentation, precision, and product integrity are non-negotiable, the TF-500 Tray Forming and Filling System sets a new standard. Designed for luxury goods, confectionery, electronics, and personal care packaging, this system ensures flawless tray formation and seamless product integration at high speeds.
Unlike traditional solutions, the TF-500 combines advanced motion control, automated 4-corner folding, and real-time vision inspection, making it the ideal choice for businesses looking to scale production while maintaining premium quality. From delicate chocolates to high-end consumer electronics, the
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Rigid Luxury Trays
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Food and Beverage
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Personal Care & Cosmetics
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Multi-Compartment Trays
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Custom-Size Trays
Reduce Costs
- Optimize Production Efficiency: Automated tray forming reduces labor costs and improves output.
- Minimized Manual Handling: Reduces operator intervention while maintaining precision.
- Material Optimization: Designed to maximize board usage and minimize waste.
Grow Your Business
- Flexible Tray Configurations: Supports multiple tray sizes and materials to meet diverse packaging needs.
- High-Precision 4-Corner Folding: ±0.4 mm accuracy ensures uniform, rigid trays every time.
- Integrated Vision Inspection: Ensures 100% defect-free trays for premium packaging.
Minimize Downtime
- Quick Product Changeover: Recipe-based automation allows seamless transitions between tray formats.
- User-Friendly Interface: Dual 15-inch touchscreens streamline system control and monitoring.
- Real-Time Production Tracking: Advanced reporting and analytics ensure peak system performance.
Watch the Tray Forming and Fulfullment System in Action
- The TF-500 automates 4-corner folding with precision, ensuring every tray is uniform and structurally sound.
- Designed for high-speed production, the system forms up to 3,500 trays per hour without compromising accuracy.
- Integrated vision-guided quality control inspects each tray in real time to ensure 100% defect-free packaging.
- Compatible with a wide range of tray sizes and board thicknesses, making it ideal for various industries.
- Vacuum-assisted product retention prevents misalignment and ensures smooth material handling during high-speed runs.
- Dual 15-inch touchscreen control panels offer an intuitive user experience and simplify product changeovers.
- Ergonomic feeder design minimizes manual intervention and optimizes material loading efficiency.
- Configurable system modules allow manufacturers to adapt tray forming workflows based on product needs.
- Handles tray sizes from 50 × 50 mm to 250 × 250 mm, accommodating diverse packaging needs.
- Supports board thicknesses from 10 to 40 pt, providing flexibility for different structural requirements.
- Operates at speeds of up to 3,500 products per hour, maximizing efficiency.
- Ensures placement accuracy of ±0.4 mm, delivering consistently high-quality tray formation.
- Modular design allows for customized tray layouts and multi-compartment configurations.
- Inline vision inspection provides real-time defect detection and reporting, enhancing quality assurance.
- Integrated motion control platform synchronizes each module, ensuring seamless performance at every stage.
- Energy-efficient components reduce power consumption while maintaining high-output performance.
Process Flow
The TF-500 Tray Forming and Filling System streamlines every stage of the packaging process, from precision tray forming and product placement to secure lid application and final delivery, ensuring high-speed, error-free operation with seamless automation.
- Base Tray Feeding: The Rotary Pick and Place system accurately picks and feeds flat tray blanks into the forming section, ensuring seamless high-speed operation.
- Base Tray Printing: The SJ Series DOD Inkjet applies high-resolution variable data, branding, or serialization directly onto the flat tray before erection.
- Base Tray Erecting: The system’s automated folding mechanism precisely forms and locks the tray structure, achieving ±0.4 mm accuracy for a rigid and reliable base.
- Base Tray Transfer: The Lugged Transport System moves the formed trays through the next processing steps, ensuring alignment and controlled positioning.
- Vac Tray Feeding and De-Nesting: The Rotary Pick and Place efficiently de-nests and feeds trays onto the line, ensuring smooth, non-contact handling for delicate or pre-formed trays
- Tray Transfer to Filling Line: Trays are accurately positioned and transferred to the filling line using the Lugged Transport System, ensuring precise movement and spacing.
- Tray Delivery for Offline Filling: Trays designated for offline filling are diverted to a secondary track, allowing for flexible production workflow.
- Tray Weight Check and Divert: The inline weighing system verifies product weight, diverting non-compliant trays to a reject lane while maintaining line efficiency.
- Tray Stacking Unit: Trays can be stacked before or after filling, optimizing storage, buffering, or secondary packaging operations.
- Tray Transfer for Lid Placement: The Lugged Transport System moves the filled trays to the lid placement section, ensuring precise alignment.
- Lid Feeding and Placement: The Rotary Pick and Place accurately picks, feeds, and places rigid lids onto each tray, ensuring seamless integration.
- Lid Positioning and Tray Closing: The system aligns and applies controlled pressure to securely position and close the lid, ensuring a tight and uniform seal.
- Double Wafer Seal Application: A security wafer label applicator applies tamper-evident double wafer seals to ensure product integrity and compliance.
- Finished Product Delivery: The completed, sealed trays are transferred to the final outfeed, ready for secondary packaging or shipping.
- System Motion Control: A fully integrated motion control system synchronizes all modules, ensuring high-speed precision and seamless automation.
- Machine Interface: The user-friendly touchscreen HMI provides real-time monitoring, system diagnostics, and recipe management for quick product changeovers.
Included Technologies
The TF-500 Tray Forming and Filling System integrates advanced automation and intelligent motion control technologies to deliver precision, efficiency, and reliability at every stage of the tray packaging process. Each component is engineered to optimize performance, ensuring seamless operation and high-speed throughput.
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.
SJ Series
DOD Inkjet
Smart Jet uses industry leading head technology to deliver UV Cured 600 DPI DOD Ink onto any surface.
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.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
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.
FG-1500
Specialty Corrugated
Folding and Finishing
Specialty 60″ Corrugated Folder Gluer with Plastics Clips and Reinforcements for POP Displays.
Specialty Folder Gluer with High Speeds and Quick Changeovers
FG-1500 specialty folder gluer series are built to enable the production of unconventional and complex products based on corrugated materials fitted with add-ons such as clips, windows, RFIDs, labels, and reinforcement inserts. FG series specialty folder gluers process E, B, C flute and double wall corrugated board with 60″ maximum blank width.
System utilizes a pick and place insert attachment, standard straight line and auto bottom functions, pre-fold and final fold sections, independently driven upper carriers with an extended final fold. Like all Pack-Smart high-performance finishing systems, the FG series are operator friendly with world-class reliability and unmatched flexibility.
POP Displays (Small)
POP Displays (Medium)
POP Displays (Large)
Advanced Capabilities
- Specifically built for unconventional and intricate products based on corrugated materials, ensuring versatility in production.
- Processes E, B, C flute and double-wall corrugated board, accommodating a wide range of packaging needs.
- Seamlessly integrates clips, windows, RFIDs, labels, and reinforcement inserts, enhancing product value and functionality.
- Ideal for creating a 60″ corrugated folder gluer with plastic clips and reinforcements, especially for POP displays.
Precision & Efficiency
- Achieves speeds of up to 2,500 PPH, optimizing production timelines.
- Ensures plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm, guaranteeing product consistency.
- Maintains front-to-back and side-to-side sheet registration within ±0.5 mm, ensuring precise alignment and folding.
- Accommodates a wide range of blank sizes, from a minimum of 4″ width and 5″ length to a maximum of 60″ width and length.
User-Friendly & Modular
- Designed with the user in mind, ensuring ease of operation and minimal training requirements.
- Allows for the addition or removal of modules as needed, adapting to evolving product requirements effortlessly.
- 100% servo-driven with digital brushless servo motors, ensuring smooth operations and reduced maintenance.
- Recommended operation with one main operator, one person for reloading, and one person on delivery, optimizing workflow and productivity.
Watch the Specialty Corrugated Folding and Finishing in Action
- Specialty Folder Gluer Design: Built specifically for unconventional and intricate products based on corrugated materials.
- Diverse Material Handling: Capable of processing E, B, C flute, and double-wall corrugated board.
- Integrated Add-Ons: Seamlessly integrates with clips, windows, RFIDs, labels, and reinforcement inserts.
- High-Speed Operations: Achieves speeds of up to 2,500 PPH.
- Accurate Affixing: Ensures plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm.
- Sheet Registration: Maintains front-to-back and side-to-side sheet registration within ±0.5 mm.
- Modular Flexibility: Allows for the addition or removal of modules as needed.
- State-of-the-Art Technology: 100% servo-driven with digital brushless servo motors.
- Advanced Diagnostics: Integrated with a virtual machine platform for system diagnostics.
- Speed: Up to 2,500 PPH
- Affixing Accuracy: Plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm
- Sheet Registration: Front-to-back and side-to-side sheet registration within ±0.5 mm
- Minimum Blank Size: Width 4”, length 5”, thickness 0.4 mm
- Maximum Blank Size: Width 60”, length 60”, thickness 6 mm
- Labor Requirements: 1 operator + 1 person reloading + 1 person on delivery
- Technological Integration: Virtual machine platform system diagnostics
- Drive System: 100% servo driven with digital brushless servo motors
Process Flow
This workflow outlines each critical stage of the corrugated folding and gluing process, meticulously designed to ensure efficiency, precision, and quality from start to finish. Follow the path from material intake to final product assembly, experiencing how integrated technologies streamline operations and elevate output.
- High-Speed Auto Feeder: Handles a broad range of materials with consistency at speeds up to 500 sheets per minute, ensuring smooth and continuous operation. Features advanced sensors and servo-driven mechanisms that adjust automatically to material thickness and size.
- Precision Placement System: Delivers materials with an exact placement accuracy of ±0.5 mm, essential for subsequent processing steps. Utilizes precision vacuum conveyors and robotic placement arms to handle materials gently and accurately.
- Cold Glue Applicator: Dispenses cold glue with pinpoint accuracy, ensuring strong, permanent bonds.
- Front and Back Fold Units: Provide versatile folding capabilities, including complex right-angle and longitudinal folds.
- Hot Melt Applicator: Applies hot melt adhesive for quick-setting, durable seals appropriate for a variety of materials.
- Plow Fold Technology: Executes high-speed inline folding, suitable for a range of production demands from simple to complex configurations.
- Sequential Lug Conveyor: Provides accurate product registration with adjustable intervals, facilitating synchronized operations in assembly lines. Features modular sections that can be configured for various product sizes, enhancing flexibility.
- Integrated Vacuum Conveyor System: Ensures precise control over product movement and placement, critical for high-speed assembly and kitting. Equipped with multiple vacuum zones that are selectively activated to handle different products securely.
- Emerald 2500 Control System
- HMI Human Machine Interface
Included FG-1500 Technologies
Each component is strategically integrated to enhance performance and reliability throughout the folding and gluing process. These technologies, from advanced feeding mechanisms to sophisticated software systems, represent the pinnacle of innovation, ensuring that every product meets the high standards of durability and design excellence expected in today’s competitive markets.
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.
HM-10
Hot Melt Glue System
Revolutionize your production with the HM-10 Hot Melt Glue System, offering precision application for a wide range of adhesive needs.
CEG-1
Cold Glue System
The CEG-1 Cold Glue System is engineered for high-precision, tamper-proof adhesive applications.
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.
PF50-90
Plow Fold Module
The PF50-90 Plow Fold Module integrates seamlessly into production lines, offering both left and right folding configurations.
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.
FG-800
Reinforced Carton
Specialty Finishing
Combine folding, gluing, affixing, personalization, and sorting in a single pass.
High Speed with Quick Changeovers
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
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 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 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.
Included Technologies
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
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.