FG-500

Automated Kitting, Carton Folding, Sealing and DOD Personalization. Master the art of folding and gluing with the FG-500, engineered for versatility and efficiency in diverse production environments.

12,000

Units per Hour

±0.4 mm

Affixing Accuracy

600 DPI

Printing Capabilities

Direct-on-Demand

Barcode Printing

The FG-500 system expertly coordinates carton kitting, gluing, folding, and personalization processes to deliver precision and efficiency in packaging operations. This robust system features inline high-accuracy affixing with a precision of ±0.4 mm and advanced 600 DPI printing capabilities, complemented by comprehensive quality assurance measures.

At the outset, all components are meticulously affixed to a flat carton carrier using fugitive glue. This prepares the carton for the application of secure glue, essential for robust packaging, followed by precise folding and compression of the front, back, and sides to form a securely sealed package.

Direct to Consumer Products

Sample Packs

Auto-Erect Cartons

  • Adapts to different materials and designs.
  • Accommodates varied production demands.
  • Allows for quick setup changes between jobs.
  • High throughput for increased productivity.
  • Consistent quality reduces waste.
  • Streamlined processes cut down production time.
  • Quick setup and easy maintenance.
  • Reliable operation with minimal interruptions.
  • Designed for easy access to components for rapid servicing.
 
  • High-Speed Feeding System: Incorporates advanced servo technology to ensure fast and accurate feeding of materials, maximizing throughput and efficiency.
  • Precision Folding Mechanisms: Utilizes state-of-the-art folding technology capable of executing complex folding patterns required for high-end packaging solutions.
  • Automated Quality Control: Integrated sensors and cameras continuously monitor the production process, detecting and correcting any deviations in real time.
  • User-Friendly Interface: Features a touchscreen HMI (Human-Machine Interface) that simplifies operation, allowing for easy adjustments and quick troubleshooting.
  • Modular Design: The system’s modular build allows for easy customization and scalability, adapting to various production demands and future upgrades.
  • Robust Construction: Engineered with durable materials and components to withstand the rigors of continuous industrial use, ensuring long-term reliability.
  • Energy Efficient Operations: Designed with energy-saving components and systems that reduce the overall environmental footprint while keeping operational costs low.
  • Safety Compliance: Fully compliant with international safety standards, featuring necessary safeguards to protect operators and machinery.
  • Operational Speed: Capable of handling up to 25,000 units per hour, depending on the product size and complexity of the tasks.
  • Product Size Compatibility: Accommodates a wide range of sizes from small cards to large cartons, with dimensions from 50 × 50 mm to 500 × 500 mm.
  • Control System: Powered by a state-of-the-art PLC integrated with an advanced motion controller for precise operations.
  • Material Handling: Suitable for a variety of materials, including paper, card stock, and lightweight corrugated materials.
  • Gluing System Options: Offers both hot melt and cold glue application systems, configurable according to product requirements.
  • Footprint and Dimensions: Occupies a standard industry footprint of 5 meters by 2 meters, with a height of 1.8 meters to accommodate integrated systems.
  • Power Requirements: Requires 380—480 V AC, 3-phase power supply, with a typical power consumption of 10 kW.
  • Air Supply Needs: Needs a clean, dry air supply of 6 bar (87 PSI), with a flow rate of 250 liters per minute.
  • Environmental Conditions: Optimal operation at temperatures from 15°C to 30°C and humidity between 30% and 70% non-condensing.

The FG-500 system is designed to streamline the production process through an efficient and integrated workflow. From initial feeding and batching to final delivery, each stage is meticulously engineered to handle various materials with precision. The FG-500’s process flow incorporates advanced feeding mechanisms, precise alignment, and automated quality control, ensuring each product is processed accurately and efficiently, ready for the next stage without delay.

  • Automatic Sheet Feeder: The FG-500 utilizes an advanced automatic sheet feeder designed to handle various types of materials efficiently. This feeder ensures continuous feed rates and precise material handling, ideal for high-volume production environments.
  • Adjustable Infeed Alignment: Equipped with precision alignment capabilities, the FG-500’s infeed system accurately aligns materials before they enter the main processing area, reducing errors and improving overall efficiency.
  • Inline Quality Control: The FG-500 integrates sophisticated sensors and cameras for real-time quality control, checking each product for defects or misalignments as they move through the production line.
  • Sequential Inserting System: This system allows for the precise insertion of additional components into packages, such as instructional leaflets or promotional materials, enhancing the packaging functionality.
  • Precision Gluing System: Implements a highly accurate gluing system that applies adhesives with precision, suitable for complex packaging formats. It can adjust for various adhesive types and application patterns.
  • Multi-Configuration Folding Module: This module allows for multiple folding configurations, accommodating a range of product sizes and complexities, from simple folds to intricate multi-fold designs.
  • Integrated Control Software: The FG-500 is controlled by a sophisticated software system that optimizes workflow, reduces downtime, and enhances productivity. It provides intuitive user interfaces and real-time diagnostics to ensure seamless operations.
  • Remote Monitoring and Diagnostics: Equipped with advanced connectivity features, the FG-500 can be monitored and diagnosed remotely, allowing for immediate troubleshooting and updates from anywhere in the world.

Key technologies include an advanced sheet feeding system, high-speed conveyors, dynamic folding units, and precise gluing mechanisms. Each component is integrated into the system to work synergistically, allowing for seamless transitions between different stages of the production process. This integration ensures consistent performance and reliability, making the FG-500 a powerhouse in automated packaging solutions.

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.

BF-100

Back Fold Module

An ultra-lightweight alloy folding attachment. The BF-100 delivers unmatched productivity for four and six-corner folding tasks.

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.

CEG-1

Cold Glue System

The CEG-1 Cold Glue System is engineered for high-precision, tamper-proof adhesive applications.

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.

DL Series

Shingled Delivery Transport

Discover the DL Series Shingled Delivery Transport, designed for efficient and ergonomic conveying of diverse printed materials.

FG-1500

Specialty 60″ Corrugated Folder Gluer with Plastics Clips and Reinforcements for POP Displays.

Up-to 2,500

Products per Hour

60″ Cartons

Max Length

±0.5 mm

Affixing Accuracy

32″

Max Clip Length

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)

  • 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. 
  • 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.
  • 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.
 
  • 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

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

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

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.

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.

HLA-500

This system is equipped with sophisticated sensors and control systems that adjust parameters in real time to suit varying material specifications and environmental conditions.

15,000

Products per Hour

±0.5 mm

Affixing Accuracy

Quick

Changeovers

<1%

Rejection Rate

1–2 People

Operators

Pack-Smart’s HLA-500 system is the fastest solution for accurate velcro label and hi/low tack tape application at speeds up to 15,000 products per hour. Because of a modular system approach, HLA-500 is ideally suited to simultaneously carry out other in-line processes such as folding and gluing, creasing, tipping, Braille embossing inspection and digital imaging. 

The system comes with your choice of delivery options, shingled, in batches, or bridging modules, for seamless integration with third-party equipment for downstream processes. 

High-Value Cartons

Specialty Packaging

  • Achieve speeds of up to 15,000 products per hour, ensuring rapid production and meeting high-demand requirements. 
  • Consistent placement accuracy of ±0.5 mm for velcro labels, hi/low tack tape, and other reclose fasteners.
  • Networked brushless servo-driven technology for the timed blank feeder ensures smooth and efficient operations.
  • Features for all cylinders ensure consistent speed and performance throughout the process.
  • Simultaneously carry out processes like folding, gluing, creasing, tipping, Braille embossing, and digital imaging.
  • Choose from various delivery options such as shingled, in batches, or bridging modules for easy integration with third-party equipment.
  • Store jobs and machine parameters with extensive diagnostics, allowing for quick setups and changeovers.
  • Ethernet and internet connectivity via laptop ensures real-time monitoring and control.
  • Stainless Steel Planetary gearheads provide longevity and reliable performance.
  • Advanced fiber-optic networked control systems ensure lightning-fast communication and real-time adjustments.
  • Adjust the system’s speed based on product requirements, ensuring optimal output.
  • Automatic speed compensation ensures consistent product handling and delivery.
 
  • Modular System Approach: Enables simultaneous execution of various in-line processes such as folding, gluing, creasing, tipping, Braille embossing, and digital imaging. 
  • Multiple Delivery Options: Offers choices like shingled, in batches, or bridging modules for diverse delivery needs. 
  • Networked Brushless Servo-Driven Technology: Ensures timely and efficient feeding of blanks. 
  • Speed Compensation: Provides consistent speed adjustments for all cylinders. 
  • Recipe Functionality: Allows for the storage of jobs and machine parameters with extensive diagnostics for quick setups. 
  • Connectivity Features: Equipped with Ethernet and internet connectivity via a laptop for real-time monitoring and control. 
  • Durable Construction: Built with Stainless Steel Planetary gearheads for longevity. 
  • Advanced Control Systems: Utilizes a fiber-optic networked control system for fast communication and real-time adjustments. 
  • Variable Speed Delivery System: Ensures optimal output by adjusting the system’s speed based on product requirements. 
  • High-Speed Belt Lifting: Features automatic speed compensation for consistent product handling. 
  • Affixing accuracy of ±0.5 mm
  • Maximum carton speed up to 30,000 cartons per hour
  • Networked brushless servo driven
  • Fiber-optic networked
  • Variable speed with batching
  • High-speed with automatic speed compensation

The process flow for the HLA-500 High-Speed Label Application System is engineered to maximize efficiency and precision. This system seamlessly integrates each step of the labeling process, from initial product feeding to final quality inspection, ensuring high-speed, accurate label application with minimal downtime.

  • Smart Feeder: Efficiently automates your document inserting processes with speed and ease. Tasks combining multiple pre-fold inserts/outserts in variable stack counts are accomplished with the utmost precision and productivity, providing a quicker return on investment. 
  • Vacuum Conveyor: High torque servo-driven vacuum transport conveys products at exacting speeds and controls product placement with 8 selectable vacuum zones.  
  • Delivery Transport: The delivery conveyor is designed with several ergonomic features minimizing fatigue of the operator when handling products in high-speed applications.
  • Barcode Scanning Module: ISO Grading and/or data capturing virtualy all types of linear 2D barcode.  Any non-conforming products are automatically diverted to ensure maximum throughput.
  • High-Speed Label Applicator: A highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications. 
  • Divert Gate: Divert non-compliant products from the product stream through a reciprocating gate. 

The HLA-500 High-Speed Label Application System incorporates state-of-the-art technologies designed to enhance performance and reliability. Key technologies include a brushless servo drive for precise control, vacuum tensioned web for stable label handling, and advanced fiber-optic sensors for accurate positioning and operation monitoring.

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.

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.

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.

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.