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.

3,500 PPH

Run Speeds

Ergonomic

Material Loading

±0.4 mm

Fold Accuracy

Tray Size

50 to 250 mm

4 Corner

Folding and Forming

Real-Time

Tracking and Reporting

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 TF-500 — Tray Forming and Fulfillment system provides the flexibility needed for diverse product applications.

  • Rigid Luxury Trays

  • Food and Beverage

  • Personal Care & Cosmetics

  • Multi-Compartment Trays

  • Custom-Size Trays

  • 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.
  • 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.
  • 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.
  • 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.

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.

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.

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.

Barcode and Data Reading
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. 

The VSC-1000 Hish-Speed Vision Scan system can manage up to 8 camera inputs with 4 parallel channels, allowing asynchronous management with real-time hardware.
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.

BA-250

High-Speed Pack-Out

Fulfillment System

Maximize efficiency with the BA-250, a fully automated pack-out fulfillment system designed for wrapping, 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 Pack-Out 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

  • 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.

Efficiently batching and bundling single products into precise groups with the batch counting and bundling module, designed for a wide range of materials and applications
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.

The VSC-1000 Hish-Speed Vision Scan system can manage up to 8 camera inputs with 4 parallel channels, allowing asynchronous management with real-time hardware.
VSC-1000

Vision Scan System

The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.

3DF-1

3D Product Feeding
System

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

3D Product Feeding System

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-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.

      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

          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

          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

          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.

          Barcode and Data Reading
          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.