AL Series
Powered Autoloader
Maximize productivity with the AL Series Powered Autoloader. Designed to extend loading capacities and reduce manual reloading for high-speed applications, ensuring continuous operation and efficiency.
TF-500
Tray Forming and
Fulfillment System
Delivers unmatched automation, producing 3,500+ products per hour while ensuring 100% product integrity. Designed for scalability, accuracy, and seamless integration, this state-of-the-art system will transform your packaging operations with modular flexibility.
Next-Generation Tray Forming & Filling — Precision, Speed, and Flexibility
In industries where presentation, precision, and product integrity are non-negotiable, the TF-500 Tray Forming and Filling System sets a new standard. Designed for luxury goods, confectionery, electronics, and personal care packaging, this system ensures flawless tray formation and seamless product integration at high speeds.
Unlike traditional solutions, the TF-500 combines advanced motion control, automated 4-corner folding, and real-time vision inspection, making it the ideal choice for businesses looking to scale production while maintaining premium quality. From delicate chocolates to high-end consumer electronics, the
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Rigid Luxury Trays
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Food and Beverage
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Personal Care & Cosmetics
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Multi-Compartment Trays
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Custom-Size Trays
Reduce Costs
- Optimize Production Efficiency: Automated tray forming reduces labor costs and improves output.
- Minimized Manual Handling: Reduces operator intervention while maintaining precision.
- Material Optimization: Designed to maximize board usage and minimize waste.
Grow Your Business
- Flexible Tray Configurations: Supports multiple tray sizes and materials to meet diverse packaging needs.
- High-Precision 4-Corner Folding: ±0.4 mm accuracy ensures uniform, rigid trays every time.
- Integrated Vision Inspection: Ensures 100% defect-free trays for premium packaging.
Minimize Downtime
- Quick Product Changeover: Recipe-based automation allows seamless transitions between tray formats.
- User-Friendly Interface: Dual 15-inch touchscreens streamline system control and monitoring.
- Real-Time Production Tracking: Advanced reporting and analytics ensure peak system performance.
Watch the Tray Forming and Fulfullment System in Action
- The TF-500 automates 4-corner folding with precision, ensuring every tray is uniform and structurally sound.
- Designed for high-speed production, the system forms up to 3,500 trays per hour without compromising accuracy.
- Integrated vision-guided quality control inspects each tray in real time to ensure 100% defect-free packaging.
- Compatible with a wide range of tray sizes and board thicknesses, making it ideal for various industries.
- Vacuum-assisted product retention prevents misalignment and ensures smooth material handling during high-speed runs.
- Dual 15-inch touchscreen control panels offer an intuitive user experience and simplify product changeovers.
- Ergonomic feeder design minimizes manual intervention and optimizes material loading efficiency.
- Configurable system modules allow manufacturers to adapt tray forming workflows based on product needs.
- Handles tray sizes from 50 × 50 mm to 250 × 250 mm, accommodating diverse packaging needs.
- Supports board thicknesses from 10 to 40 pt, providing flexibility for different structural requirements.
- Operates at speeds of up to 3,500 products per hour, maximizing efficiency.
- Ensures placement accuracy of ±0.4 mm, delivering consistently high-quality tray formation.
- Modular design allows for customized tray layouts and multi-compartment configurations.
- Inline vision inspection provides real-time defect detection and reporting, enhancing quality assurance.
- Integrated motion control platform synchronizes each module, ensuring seamless performance at every stage.
- Energy-efficient components reduce power consumption while maintaining high-output performance.
Process Flow
The TF-500 Tray Forming and Filling System streamlines every stage of the packaging process, from precision tray forming and product placement to secure lid application and final delivery, ensuring high-speed, error-free operation with seamless automation.
- Base Tray Feeding: The Rotary Pick and Place system accurately picks and feeds flat tray blanks into the forming section, ensuring seamless high-speed operation.
- Base Tray Printing: The SJ Series DOD Inkjet applies high-resolution variable data, branding, or serialization directly onto the flat tray before erection.
- Base Tray Erecting: The system’s automated folding mechanism precisely forms and locks the tray structure, achieving ±0.4 mm accuracy for a rigid and reliable base.
- Base Tray Transfer: The Lugged Transport System moves the formed trays through the next processing steps, ensuring alignment and controlled positioning.
- Vac Tray Feeding and De-Nesting: The Rotary Pick and Place efficiently de-nests and feeds trays onto the line, ensuring smooth, non-contact handling for delicate or pre-formed trays
- Tray Transfer to Filling Line: Trays are accurately positioned and transferred to the filling line using the Lugged Transport System, ensuring precise movement and spacing.
- Tray Delivery for Offline Filling: Trays designated for offline filling are diverted to a secondary track, allowing for flexible production workflow.
- Tray Weight Check and Divert: The inline weighing system verifies product weight, diverting non-compliant trays to a reject lane while maintaining line efficiency.
- Tray Stacking Unit: Trays can be stacked before or after filling, optimizing storage, buffering, or secondary packaging operations.
- Tray Transfer for Lid Placement: The Lugged Transport System moves the filled trays to the lid placement section, ensuring precise alignment.
- Lid Feeding and Placement: The Rotary Pick and Place accurately picks, feeds, and places rigid lids onto each tray, ensuring seamless integration.
- Lid Positioning and Tray Closing: The system aligns and applies controlled pressure to securely position and close the lid, ensuring a tight and uniform seal.
- Double Wafer Seal Application: A security wafer label applicator applies tamper-evident double wafer seals to ensure product integrity and compliance.
- Finished Product Delivery: The completed, sealed trays are transferred to the final outfeed, ready for secondary packaging or shipping.
- System Motion Control: A fully integrated motion control system synchronizes all modules, ensuring high-speed precision and seamless automation.
- Machine Interface: The user-friendly touchscreen HMI provides real-time monitoring, system diagnostics, and recipe management for quick product changeovers.
Included Technologies
The TF-500 Tray Forming and Filling System integrates advanced automation and intelligent motion control technologies to deliver precision, efficiency, and reliability at every stage of the tray packaging process. Each component is engineered to optimize performance, ensuring seamless operation and high-speed throughput.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
SJ Series
DOD Inkjet
Smart Jet uses industry leading head technology to deliver UV Cured 600 DPI DOD Ink onto any surface.
VSC-1000
Vision Scan System
The VSC-1000 Vision System offers state-of-the-art vision scanning and real-time image processing, ideal for high-speed production environments.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
RPP Series
Reciprocating Pick and Place Series
Maximize your production efficiency with the RPP Series, designed for high-speed, accurate handling of delicate materials and uniquely shaped products.
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.
Revolutionize Pack-Out with Precision Automation
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.
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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.
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.
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.
MD-200
Multi-Stream Finishing
and Packaging System
Elevate your medical kit production with the MD-200, a multi-stream system engineered for high efficiency and precision in assembling and packaging medical-grade antigen test kits.
Unmatched Efficiency in Medical Kit Production
The MD-200 streamlines the final assembly of medical kits through its advanced multi-lane capabilities. Each production lane meticulously adds components, folds carriers, applies DOD serialization, and securely guides kits into wrapping modules, enhancing throughput and precision.
Medical Kits
Pharmaceutical Products
Fast Moving Consumer Goods
Efficiency
- Multiple-stream technology supports simultaneous kit assembly.
- Achieves a production speed of 200 PPM, optimizing throughput.
- Quick changeover capabilities minimize downtime between production runs.
Precision
- Advanced servo-driven system ensures precise component placement.
- DOD serialization for accurate tracking and compliance.
- Real-time data tracking and validation enhance product integrity.
Cost-Effectiveness
- Reduces labor costs with automated multi-lane processing.
- Lowers per-unit production costs through efficient design and operation.
- Minimizes waste with precise material handling and usage.
Watch the Multi-Stream Finishing and Packaging
System in Action
- Multi-Lane Configuration: Simultaneously assembles multiple kits, increasing throughput.
- Integrated DOD Inkjet Printing: Offers high-resolution serialization directly on components, enhancing traceability.
- Automated Quality Control: Utilizes advanced sensors and cameras to ensure each kit meets exact specifications.
- Servo-Driven Precision: Features digital brushless servo motors for precise motion control throughout the assembly process.
- Real-Time Data Monitoring: Incorporates a system for instant data tracking and validation to ensure production accuracy.
- Advanced User Interface: Equipped with a sophisticated HMI (Human Machine Interface), enabling easy control and monitoring of the system.
- Throughput Capacity: Capable of handling up to 200 kits per minute, optimizing production efficiency.
- Quick Changeover: System design allows for rapid adjustments, with changeovers taking just 2–3 minutes.
- Serialization Technology: Utilizes Drop-on-Demand (DOD) inkjet printing at 600 DPI for detailed and durable markings.
- Material Handling: Designed to work with a variety of packaging materials, including sensitive medical components.
- Operational Dimensions: Accommodates multiple lanes with adjustable settings to handle different kit sizes and configurations.
- Compliance and Safety: Meets high standards for medical device production, ensuring compliance with regulatory requirements.
Process Flow
The MD-200 Metal Detector plays a crucial role in the quality assurance process by integrating seamlessly into the production line to detect metallic contaminants. Products pass through the detector, where high-sensitivity sensors scan for any metal fragments. Upon detection, the system signals the rejection mechanism, promptly removing the contaminated product from the line.
- Single-Stream Buffer Transport Module: Manages the flow from upstream assembly to maintain continuous production without bottlenecks.
- RP300 Rotary Pick and Place Feeder: Accurately places components into the system with high precision, preparing them for wrapping and sealing.
- E10 Wrapper with 4-Side Seal: Ensures each medical kit is securely sealed, maintaining product integrity and sterility with precise four-side sealing.
- DF400 Desiccant Feeder with Bulk Unwind Station: Integrates desiccants into the packaging, cut and dispensed synchronously with the packaging speed.
- SJ75 DOD Inkjet System with Controller: Applies high-resolution UDI codes and other critical information directly onto the packaging film.
- DV250 Divert Module: Diverts any non-conforming kits out of the production line, ensuring only products that meet quality standards proceed.
- VSC1000 Vision Scan Camera: Inspects all print work for accuracy, clarity, and placement, ensuring compliance with quality standards.
- HMI10 Human Machine Interface and Allen-Bradley System Motion Control: Provides central control and monitoring of the entire system, allowing adjustments and real-time tracking.
- Delta-X Tracker Real-Time Data Controller: Offers end-to-end data traceability, tracking critical data for compliance and production efficiency.
Included Technologies
The MD-200 leverages Delta-X software for real-time control and end-to-end reporting, ensuring precision in medical kit assembly. Its servo-driven mechanisms enhance placement accuracy and speed, while its seamless integration with high-speed DOD printing meets stringent regulatory demands, significantly boosting throughput with minimal downtime.
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.
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.