• 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

• 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.

• 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

• 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. 

• Dynamic Card Feeding: Ability to selectively feed up to 6 different card bodies simultaneously, enabling diverse card issuance without changeovers. 
  
• Simultaneous Encoding: Innovative encoding wheel that encodes 24 cards at once, optimizing the encoding process. 
  
• High-Speed Printing: Utilizes 4-colour DOD print technology with UV-curable inks for fast, high-resolution card printing. 

• Advanced Security: Chip cards developed through unique encryption methods with Pack-Smart’s Delta-X Data Management Platform. 
  
• Integrated Verification: Ensures each card’s print matches the input file, guaranteeing accuracy and quality. 
  
• Modular Design: Allows for easy integration of additional features, ensuring adaptability to evolving market needs. 

• Up to 10,000 cards per hour
  
• 24 cards simultaneously
  
• Up to 6 different card bodies at once
  
• 4-colour DoD print with UV-curable inks
  
• Chip cards with unique encryption methods

• Integrated print verification system
  
• Fiber optic networked system
  
• Delta-X Software with end-to-end tracking and configurable workflows
  
• Supports Sequential, Random, and One Recipe workflows

• Pressure Sensitive Label Application: Applies pressure sensitive labels at high speeds and accuracy for the most demanding precision-critical applications. 
  
• High-Speed Label Applicator: Printer can selectively inhibit labels — meaning it can add or not add a label.  

• Drop-on-Demand Inkjet (4 colours): Can dynamically print each run, compared to traditional printers, which can only print the same identical image each run. Edge-to-edge printing, meaning the printer prints beyond the edges of the card (bleeds over the edge) to ensure the card is fully covered. 
  
• DOD Inkjet: Smart Jet uses industry-leading head technology to deliver UV-cured 600 DPI DOD Ink onto any surface at speeds over 500 feet per minute.

• Card Surface Plasma Treatment: Cleans debris buildup on a card and keeps the card warm so ink adheres properly. On the back of the card, 3 plasma guns are used so that the MAG strips are not interrupted. Front of the card uses 6 plasma guns to treat the full width. 
  
• Ionizer: Stops the card from misting to protect it from distortion. Without an ionizer, static builds up, and this leads to jet out where white lines appear through the card. 
  
• LED UV Curing: The UVL features a high-power LED UV lamp intended for high-speed, single-pass drying or curing applications.  

• Chip Encoding: The high-speed encode module combined with the pogo pin contact interface allows easy integration with the customer’s existing infrastructure and provides a solid return on investment.  
  
• Mag Encoding: The module supports encoding magnetic stripes from top and bottom. The system can be configured with two or three-track read and write heads, providing reliable magnetic stripe encoding capabilities. 

• Print Inspection & Validation: OCR (optical character recognition) verification that can read text that’s been printed. Can read 1D/2D barcodes, such as QR codes. 
  
• Label Placement Inspection: Label inspection counts the number of black pixels and checks that the pixel count is below the 2000 black pixel threshold.

• Card Turnover & Re-registration: Uses a belt/band to turn the card over 180° in case printing on the back side is required. Can be replayed with straight-through. 
  
• Rejection: Divert non-compliant products from the product stream through reciprocating gate.

• Tamper-evident package security with hybrid adhesive seal and extended compression
• Batching, flow-wrapping, bundle labeling, and case and pallet manifest
• Automatic reissue of rejected cards, packs or bundles and on-the-fly bundle remake system

• Real-time data matching, tracking, validation and end-to-end reporting
• Virtual machine platform and system diagnostics
• 100% servo driven with digital brushless servo motors

• Inline card personalization, carrier affixing, secure packaging and pack-out speeds up to 20,000 PPH
• Duplex card personalization speeds up to 35,000 PPH
• Drop-on-demand UV printing at 600 DPI (3.5 pL drop size)

• Edge-to-edge affixing accuracy of ±0.5 mm in portrait and landscape orientation
• Labor: 1 operator + 2 person reloading + 1–2 people on delivery

• DOD inkjet printing: High-resolution drop-on-demand variable printing with 600 DPI at speeds up to 500 ft/min. Field replaceable Piezo print head with 3.5 pL drop volume and 75 mm print width (1D & 2D barcode, SIM ICCID, redemption code, card numbers, logos and graphics).
  
• Labelling: Apply all varieties of pressure-sensitive labels at line speeds up to 660 ft/min (400 labels per minute) and placement accuracy of ±0.4 mm (scratch-off, activation, magnetic stripe, RFID tag application). Minimize reloading frequency and increase productivity with up to 560 mm roll diameter.
  
• Magstripe encoding: Reverse, condensed, JIS encoding, with Hi-Co/Lo-Co coercivity selection at speeds of 35,000 cards per hour. Head lifespan over 100 million cycles.
  
• UV Curing: Single pass curing with high-powered LED UV lamp. Achieve an 85% increase in energy efficiency compared to standard arc or microwave technologies.

• Plasma treatment: Rapidly micro cleaning card surfaces and raising surface energy to improve wettability and adhesion of glue, inks, and coatings. Adjustable maximum power of 500 W with 50 mm performance width.
  
• Dual-belt vacuum transport: Independent personalization belts for ease of cleaning and prevention of premature cracking.
  
• Turnover and re-registration: Inline duplex personalization for improved productivity with modular design for quick changeover to straight-through card transport.
  
• Barcode grading: Ensures the production of high-quality products through verification of scan ability and compliance with barcode verification standards. Instantly identify B and C grade barcodes to reduce defect rates and associated costs from wasted material. Ability to run the Personalization section offline.

• Fugitive glue: Attach card to carries with low tack glue dots for reduced consumable cost.
• PSA adhesive label: Attach the card to carriers with pressure-sensitive labels.
  
• Cold glue: Tamper evident seal is accomplished with fibre crosslinking cold glue, which replaces legacy pressure seal applications.
  
• Extended compression: Ensure glue is fully cured and performing at speeds 10x faster than legacy pressure seal technology.

• Edge-to-edge card affixing: Modular alignment technology allows transferring cards and attaching to carriers with ±0.020” accuracy.
  
• Folding in all directions: With flexible folding options, including front, back, and plow fold, accommodate any type of form packaging factor with quick changeover times.
  
• Carrier printing & personalization: Print an activation barcode inline or apply a magnetic stripe label and match the card activation data.

• Batching and bundling: File-controlled dynamic batching allows for predetermined sequential bundling
  
• Shrink or flow wrapping: With options for bundle packaging, ensure your end products meet the customer’s requirements
  

• Labelling: Track piece-level sequence and provide an aggregated label for downstream distribution
  
• Pallet manifest: Provide complete card-to-pallet aggregation reporting

General

• Save recipes for module configurations to improve changeover and setup time
• Multi-level customizable user access for every single functionality of the software
• Data logger to create report files for details of every product exiting the final conveyor
• Define limit for sequential errors on sensors/data acquisition units checking the product status; the tracking system will trigger a fault when the maximum allowed consecutive errors occur

Data Integrity

• Match data between perso line and affixing line cameras to ensure accurate sequential product feed
• Log acquired data to a database file or verify the accuracy of scanned data by comparison to a database file
• Connect with centralized camera control unit for shared interface and communication with all cameras
• Tag non-conforming products after data matching or QC inspection for signalling to downstream modules Reproduction
• Generate a remake database for remaking diverted products while in production (on-the-fly reproduction) or after the current job has finished (end-of-job reproduction)

Batching

• Control batching rules for conditional batching based on tagged or remade products
• Track and signal divert for compensating batch counts
• Integration with relational databases (SQL, MySQL, Oracle, etc.) or ERP

Data Mapping & Integration

• Integration with relational databases (SQL, MySQL, Oracle, etc.) or ERP
• Tracking engine transmits print information to inkjet for printing 1D/2D barcodes, alphanumeric, counters, and more with multi-language support

Product Registration

• Sequential production by assigning the first record of the source database to the product passing through the registration sensor
• Dynamic production by mapping data from the data acquisition module to the source database
• Synchronize products as they move down the production line with product reregistration sensors on each belt for precise printing, reading, and tracking

• High-Speed Production: Capable of achieving speeds up to 13,000 UPH, optimizing production timelines.
  
• Precision Placement: Offers card and component placement accuracy of ±0.020″, ensuring each product meets the highest quality standards.
  
• Integrated Verification Systems: Built-in systems that track products throughout the production process, ensuring all errors are identified, diverted, and addressed.
  
• Virtual Machine Platform: 100% servo-driven system that provides unmatched reliability and flexibility.
  
• Multiple Component Inserting: Capability to insert various components seamlessly.

• Full Data Capturing and Reporting: Comprehensive system that tracks product data, provides insights, and generates detailed reports on any issues, allowing for real-time adjustments.
  
• Modular Design: A building block approach that allows customers to tailor the system to their specific needs, both at the time of purchase and in the future.
  
• End-to-End Solutions: Comprehensive solutions that cover everything from batching to wrapping and labelling bundles.
  
• Package and Component Personalization: Offers in-line personalization of cards, carriers, and more in a single system pass.

• Speed: Up to 13,000 UPH
  
• Placement Accuracy: Card and component placement accuracy of ±0.020”
  
• Personalization: 300—600 DPI DoD printing
  
• Recipe Storage: 20 recipes with additional storage available
  
• System Width: 38″
  
• System Length: 535.5″

• System Drive: 100% servo driven with digital brushless servo motors
  
• Uptime: Upwards of 95%
  
• Minimum Material Size (Width × Length × Thickness): 1.25″ × 1.25″ × 0.01″
  
• Maximum Material Size: 9″ × 20″ × 0.17″
  
• System Height: 69.5″

• Rotary Pick & Place with Realignment: Employs vacuum pressure for precise card and carrier placement, managed by software for optimal alignment accuracy.
  
• Vacuum Transport: Ensures smooth and stable transport, with software monitoring speed and stability to prevent misalignments.

• Smart Feeder: Feeds cards and carriers into the system, with software adjustments allowing for variations in material handling.

• DoD Inkjet and UV Drying: Delivers high-resolution printing with UV curing, software-controlled for precise ink deposition and curing times.
  
• Magstripe Encoder: Encodes magnetic stripes, with software ensuring correct encoding settings and verifying stripe quality.

• Camera Verification System: Uses Optical Character Recognition (OCR) to check print and encode quality, with software directing automatic corrections.

• Hot Melt Glue Application: Applies adhesive under software control to ensure consistent glue patterns and volumes.
  
• Plowfold: Mechanically folds the carrier, with software timing the folds to match the throughput speed.

• Front Fold and Bump & Turn: Additional folds and reorientation are tightly controlled by software to maintain precise alignment and packaging integrity.

• Scratch-Off Label Application: Software schedules and controls the application of scratch-off labels, integrating security features as required.
  
• Print and Apply Labelling: Final labeling is controlled by software, ensuring labels are accurately placed and contain correct information.

• Operator Interface with 15″ Screen: Provides a central hub for operators to interact with the system’s software, offering real-time diagnostics, adjustments, and feedback on system performance.

Delta-X Real-Time Controller

• System Oversight and Data Traceability: The advanced Delta-X controller manages all operational parameters, maintaining data integrity and traceability across the process. It supports predictive analytics for maintenance, on-the-fly adjustments for product setups, and detailed reporting for quality assurance.

High-Speed Performance

• Industry-leading speeds of up to 30,000 PPH
• Optimized end-to-end solutions, including batching, wrapping, and labelling bundles

Integrated Verification Systems

• Consistent quality checks throughout the production process
• Automated error detection and diversion to ensure product accuracy
• Remake initiation for guaranteed 100% verified products

Comprehensive Software & Hardware Platform

• Powered by Pack-Smart Inc.’s robust virtual machine software/hardware platform
• Rugged fiber-optic network ensures reliable data transfer and processing
• Customizable report compliance interface for tailored data insights

Versatile Card Handling

• Efficient management of diverse card formats, including CR80s, M6 hang tags, and custom-shaped cards
• Personalization features such as magstripe label affixing, 1D and 2D barcode printing, and scratch-off label application

Modular & Adaptable Design

• Tailored solutions to meet specific production needs
• Future-proof design allows for system customization and integration of new features

• Speed: Up to 30,000 UPH
• Personalization: Magstripe label affixing, 1D and 2D barcode printing, scratch-off label application

• Card Formats Supported: CR80s, M6 hang tags, and many custom-shaped cards
• Verification: Integrated systems for product tracking and error detection

• Feeding, Registration and Alignment: Rotary Pick and Place Feeder consistently feeds, inserts, attaches, and batches delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
  
• Smart Chip Encoding: Pack-Smart’s SCE-1 Smart Card Encoding module is designed to provide a versatile drop-in enhancement for CP-250 systems to benefit from expanded EMV and contact/contactless card encoding capabilities. The high-speed encode module combined with pogo pin contact interface allows easy integration with customers’ existing infrastructure and provides a solid return on investment. 
  
• Magnetic Strip Encoding: High-speed and modular magnetic encoding solution designed with advanced and industrial-grade electronics and integrated magnetic stripe encoding software. Module supports encoding magnetic stripes from top and bottom. System can be configured with two or three-track read and write heads, providing reliable magnetic stripe encoding capabilities. Card personalization of products of any size and shape in compliance with ISO standards.

• DOD Variable Print: Smart Jet uses industry-leading head technology to deliver UV-cured 600 DPI DOD Ink onto any surface at speeds over 500 feet per minute. Up to 8 heads can be combined to reach widths of 575 mm for full web or press sheet personalization.
  
• UV Drying: The UVL features a high-power LED UV lamp intended for high-speed, single-pass drying or curing applications. The air-cooled LED lamp allows for an 85% increase in energy consumption as compared to traditional, long lifecycle, easy setup, and minimal maintenance for a high-efficiency process compared to typical arc or microwave technologies. The UVL reduces wear on conveyor belts and enables compatibility with heat-sensitive substrates.

• Label Application: High-Speed Label Applicator is an asset in any demanding manufacturing environment. With the ability to apply all varieties of pressure-sensitive labels at line speeds up to 200 m/min (660 ft/min), the HSL-60 can apply 400 labels per minute, with a best-in-class placement accuracy of ±0.4 mm. Depending on material and label size, Pack-Smart HSL-60 Labeller will accurately apply labels to any product in line with any printing, converting and packaging production lines. When operating in a “Zero Downtime“ configuration, the HSL-60 tandem system allows for safe “on the fly” roll changes eliminating downtime required for roll changes.

• Inspection, Verification & Placement Inspection: Area Scan Vision will inspect variable OCR, barcode, and ANSI verification, as well as perform print and placement quality checks. The native 64-bit environment alongside the Xenon processors allows image processing as fast as 120 FPS.

• Divert & Rejection: The DV Series Divert Modules are responsible for removing non-conforming products from the production line. High-speed ejecting cylinders governed by Data Tracking and Machine Logic controllers are activated in real time to ensure 100% conforming products are delivered. Fail safe sensors track product rejection to ensure assumption free operation.

• Product Delivery: The delivery conveyor is designed with several ergonomic features minimizing fatigue of the operator when handling products in high-speed applications. Two stage height adjustment on each end of the conveyor allows for quick adjustment of table elevation, based on operator preference. Variable speed with batching ability provides gaps eliminating needs for counting finished product, while increasing productivity. Four-inch locking casters are a standard feature of DL 500 providing outstanding mobility.

• Save recipes for module configurations to improve changeover and setup time.
• Multi-level customizable user access for every single functionality of the software.

• Data logger to create report files for details of every product exiting the final conveyor.
• Define the limit for sequential errors on sensors/data acquisition units checking the product status. The tracking system will trigger a fault when a maximum allowed consecutive errors occur.