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.
BA-250
High-Speed Automated
Pack-Out and Fulfillment
System
Maximize efficiency with the BA-250, a fully automated pack-out and fulfillment system designed for wrapping, inline batching, bundling, and labeling, enhancing throughput up to 2,000 bundles per hour.
Revolutionize Pack-Out with Precision Automation
The BA-250 Automated Pack-Out and Fulfillment System is Pack-Smart’s state-of-the-art solution for inline batching, wrapping, and aggregate labeling, delivering up to 2,000 finished bundles per hour with precision and reliability.
This advanced system seamlessly integrates key functions, including batching, wrapping, scanning, weighing, and quality assurance. Each bundle, case, and pallet is labeled with pinpoint accuracy, streamlining workflow efficiency and ensuring end-to-end traceability for high-demand production environments.
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Fast Moving Consumer Goods
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Pharmaceutical Products
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Open Loop Cards
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Closed Loop Cards
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Membership & Loyalty
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Serialized Products
Streamlined Production
- Enhances on-time delivery with integrated packaging processes.
- Produces up to 2,000 bundles per hour, accelerating market readiness.
- Fully automated system reduces the need for manual intervention, lowering labor costs.
Quality Assurance
- Incorporates a QA station that rejects and remakes bad products on the fly.
- Ensures 100% product integrity and quality with advanced scanning and weighing technologies.
- Automated labeling system maintains accuracy and consistency across all bundles.
Advanced Integration
- Utilizes camera-based aggregation to ensure precise product grouping.
- Weight verification of each bundle confirms the correct number of products before packaging.
- Delta-X control system offers real-time data traceability and advanced reporting capabilities.
Watch the Pack-Out Fulfillment System in Action
- High-speed vibratory bowl for product alignment
- Redundant buffering systems to maintain continuous operation
- Advanced rotary motion pick and place for precise product placement
- Integrated weighing and scanning for accurate quality control
- Servo-controlled system for flexible and efficient operation
- Capacity: Up to 2000 finished bundles per hour
- Label placement accuracy: ±1 mm
- Rejection rate: Less than 2%
- Power requirements: 230 V AC, 3 phase, max 30 A
Process Flow
The BA-250 exemplifies streamlined operational excellence, featuring a process flow that optimizes speed and precision. From material handling to the final inspection, each stage of the process is meticulously engineered to enhance productivity and ensure the highest quality output.
- VF900 Vibratory Bowl Feeder: Utilizes vibration technology to orient and sort products efficiently, ensuring they are correctly sequenced for packaging.
- Axode Camera System: Scans and verifies each product for correct sequence and range, enabling accurate tracking and initiation of variable print and apply label content.
- Transport Conveyor: Moves the verified products into the batching module, maintaining a consistent flow to optimize the handling process.
- BC20-03 Batching Module: Collects products and organizes them into specified counts or sequences, preparing them for bundling.
- Alma Flow Wrapper: Encases grouped products in a protective wrap, securing them for the labeling process.
- PAP3000 Print and Apply Labeler: Automatically generates and applies labels to each bundle, ensuring each package is accurately labeled with essential tracking information and product details.
- Weigh Check Module: Conducts a detailed weight verification of each packaged bundle to ensure it contains the correct number of products, essential for maintaining quality control.
- Bundle Divert System: Actively diverts bundles that do not meet specified criteria (e.g., incorrect product count or mislabeling) for reprocessing, ensuring only conforming products proceed to final packaging.
- Hardy Check Weight Module: Provides a secondary verification to re-confirm the accuracy of each bundle’s weight, facilitating a final quality check before the products are cleared for dispatch.
- HMI10 Human Machine Interface: Offers a user-friendly interface for system control and monitoring, allowing operators to make real-time adjustments and respond to system alerts efficiently.
- Delta-X Real-Time Data Controller: Governs the entire system, providing advanced data traceability, integrity reporting, mix-up prevention, predictive analytics, and maintenance scheduling. This technology ensures high operational reliability and repeatability in product setups.
Included Technologies
The BA-250 integrates a suite of cutting-edge technologies that elevate its operational capabilities. It incorporates advanced sensors for real-time monitoring, precision actuators for accurate material handling, and sophisticated software for seamless automation. These technologies work in harmony to ensure the BA-250 delivers exceptional performance, making it a robust solution for industries seeking to leverage technological advancements for improved efficiency and quality.
BC Series
Batch Counter & Bundling
Efficiently batch single products into precise groups with Pack-Smart’s BC Series, designed for a wide range of materials and applications.
DZ Series
Zoned Divert Gate System
Elevate efficiency with the DZ Series Zoned Divert, designed for precise sorting and high-capacity handling in demanding industrial environments.
HSL-60
High-Speed Label Applicator
The HSL-60 is a highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
FG-500
Specialty Carton
Folding and
Finishing System
Automated Kitting, Carton Folding, Sealing and DOD Personalization. Master the art of folding and gluing with the FG-500 specialty carton folding and finishing system, engineered for versatility and efficiency in diverse production environments.
Streamline Your Production with Advanced Folding and Gluing
The FG-500 specialty carton folding and finishing 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
Enhance Flexibility
- Adapts to different materials and designs.
- Accommodates varied production demands.
- Allows for quick setup changes between jobs.
Boost Efficiency
- High throughput for increased productivity.
- Consistent quality reduces waste.
- Streamlined processes cut down production time.
Minimize Downtime
- Quick setup and easy maintenance.
- Reliable operation with minimal interruptions.
- Designed for easy access to components for rapid servicing.
Watch Specialty Carton Folding
and Finishing in Action
- 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.
Process Flow
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.
Included Technologies
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.
HLA-500
High-Speed Label
Application System
This high-speed label application system is equipped with sophisticated sensors and control systems that adjust parameters in real time to suit varying material specifications and environmental conditions.
Flexible High-Speed Label Application for Print Finishing
The HLA-500 High-Speed Label Application System applies pressure-sensitive labels, Velcro labels, and hi/low-tack tape to high-value cartons and specialty packaging at speeds up to 15,000 products per hour. Designed for accurate placement and fast job changeovers, the system supports ±0.5 mm affixing accuracy across demanding print finishing workflows.
Built on a modular platform, the HLA-500 can integrate additional inline processes such as folding, gluing, creasing, tipping, Braille embossing, inspection, and digital imaging. Finished products can be delivered shingled, batched, or transferred through bridging modules for seamless connection to downstream third-party equipment.
High-Value Cartons
Specialty Packaging
Speed & Precision
- 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.
Modular Design & Integration
- 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.
State-of-the-Art Control Systems
- 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.
Watch the High-Speed Pressure Sensitive
Label Application System in Action
- 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
Process Flow
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.
Included HLA-500 Technologies
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
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.
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.
FG-800
Reinforced Carton
Specialty Finishing
System
Single-pass reinforced carton finishing system that combines folding, gluing, component affixing, personalization, and sorting for high-value and auto-erect cartons.
High-Speed Reinforced Carton Finishing with Quick Changeovers
The FG-800 Reinforced Carton Specialty Finishing System gives manufacturers the flexibility to produce high-value folding cartons, reinforced cartons, and auto-erect cartons in one configurable workflow. It combines carton registration, folding, gluing, component affixing, personalization, and sorting without moving work between separate finishing steps.
Built on a servo-driven platform with fiber-optic controls, the FG-800 supports quick make-readies, hot and cold glue application, rotary pick-and-place feeding, and flexible inline folding modules. This allows producers to run multi-substrate carton designs with speeds up to 10,000 PPH, carton widths up to 30 inches, and ±0.4 mm affixing accuracy.
High Value Carton
Auto-Erect Cartons
Advanced Flexibility & Precision
- State-of-the-Art Registration: Utilizes innovative servo technology for swift and effortless carton alignment.
- Versatile Folding Modules: Exceptionally flexible inline folding modules ensure quick make-readies for diverse carton packages.
- Accurate Affixing: High-speed Rotary Pick and Place Feeders for precise feeding and affixing of a wide range of materials, including corrugated, rigid, and uniquely shaped items.
- Affixing Accuracy: Achieves an impressive accuracy of ±0.4 mm.
Comprehensive Integration & Efficiency
- All-in-One Solution: Combines folding, gluing, affixing, personalization, and sorting capabilities in a single pass, enabling the creation of unique multi-substrate based folding cartons.
- Advanced Gluing Technology: Equipped with both hot and cold glue technology, installed with flexible mounting attachments for versatility within the gluer.
- High Throughput: Achieves speeds of up to 10,000 PPH with the capability to handle cartons up to 30″ in width.
Cutting-Edge Technology & Design
- Fiber Optic Network: Built on a state-of-the-art fibre optic network, ensuring seamless communication and operations.
- Brushless Servo-Technology: Employs advanced motion control for unparalleled production flexibility and throughput.
- Diverse Folding Capabilities: Offers front fold, back fold, plow fold, and auto-erect cartons, catering to high-value carton processing needs.
- Related Integration: Compatible with the RP Series, further expanding its capabilities.
Watch the Reinforced Carton Specialty
Finishing System in Action
- State-of-the-Art Registration Module: Employs innovative servo technology for precise carton alignment, ensuring consistent quality.
- Versatile Folding Capabilities: Equipped with inline folding modules that allow for front fold, back fold, plow fold, and auto-erect cartons, catering to a wide range of packaging needs.
- Advanced Gluing System: Incorporates both hot and cold glue technologies, adaptable within the gluer through flexible mounting attachments.
- Brushless Servo-Technology: Utilizes advanced motion control for unparalleled production flexibility and throughput.
- High-Speed Rotary Pick and Place Feeders: Designed for fast and accurate feeding and affixing of various materials, from corrugated to rigid and uniquely shaped items.
- Multi-Functional Capabilities: Combines folding, gluing, affixing, personalization, and sorting in a single pass, maximizing production efficiency.
- Fiber Optic Network Integration: Built on a state-of-the-art fiber optic network, ensuring seamless operations and communication between modules.
- Throughput: Up to 10,000 PPH
- Affixing Accuracy: ±0.4 mm, ensuring precise placement and adherence of materials
- Carton Width Capacity: Up to 30 inches
- Processed Material Types: Specializes in high-value carton and auto-erect cartons
- Gluing Technologies: Equipped with both hot and cold glue systems, adaptable for various packaging needs
- Related Compatibility: Seamlessly integrates with the RP Series for expanded capabilities
Interactive Process Flow
The process flow for the FG-800 Reinforced Carton Specialty Finishing System is designed to ensure precise, secure, and efficient production of folding cartons. This system integrates each step, from initial material feeding and registration to final gluing and finishing, ensuring high-speed, accurate application with robust security measures.
- Friction Feeder: The FG-800 utilizes the FF1500 Friction Feeder, which ensures consistent and reliable feeding of corrugated blanks into the system. This feeder is designed to handle a variety of materials, maintaining high speeds and precision.
- Registration Module: The registration module aligns the material positioning and spacing between incoming blanks, ensuring accurate processing throughout the production line.
- Friction Feeder: FF Series friction feeders are designed with a solid steel construction to ensure stability and high performance even in the toughest environments, resulting in high production speeds of up to 600 PPH.
- Hot Glue System: The HM10 Hot Melt Secure Glue System applies hot glue for tamper-resistant and secure enclosure gluing. This system ensures a strong bond that is essential for high-security applications.
- Rotary Pick and Place Feeder: Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
- Cold Glue System: The CEG1 Cold Extruded Glue System applies cold glue, providing a tamper-evident seal. This system is ideal for applications requiring high levels of security and precision.
- Plow Fold Module: The PF50-90 Plow Fold Module can fold sheets and booklets at high speeds, accommodating both left and right folds. It is versatile, allowing for tool-less adjustments to meet various folding requirements.
- Vacuum Transport: The VC1500-12 Vacuum Transport module provides smooth and efficient variable speed transport for the host blanks, ensuring that materials move through the system without disruption.
- Front Fold Module: The MFF120 Front Fold Module ensures precise folding of materials, using air jets and hooked arms to achieve accurate folds. This module is essential for creating high-quality finished products.
- Extended Compression: This feature ensures that the glue is fully cured at speeds 10 times faster than legacy pressure seal technology, enhancing the strength and durability of the final product.
- Delta-X Data Management Platform: The Delta-X software provides real-time tracking, configurable workflows, and batch processing. This system ensures that all production data is accurately tracked and managed, enhancing overall operational efficiency.
- HMI-10 Interface: The HMI-10 graphic interface connects operators with the machine, combining a PLC and HMI into one unit. This interface offers intuitive controls and real-time data, facilitating easy operation and management of the FG-800 system.
Included Technologies
The FG-800 Reinforced Carton Specialty Finishing System incorporates advanced technologies to enhance its performance and reliability. Key technologies include high-speed friction feeders, precision affixing mechanisms, advanced folding modules, and real-time data management systems. These technologies work together to ensure consistent, high-quality production of folding cartons.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
FF Series
Primary Friction Feeder
The FF Series Friction Feeder can handle the lightest paper and is equally at home when dealing with heavy stock materials when called upon.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
HSL-60
High-Speed Label Applicator
The HSL-60 is a highly versatile module that applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications.
SF Series
Secondary Friction Feeder
Reaching up to 600 products per minute, the SF Series is a perfect choice for handling light paper to heavy stock material.