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.
HYPERVISION 3500
Multi-Layer Vision and Lamination Inspection System
Precision Secure Document Inspection System at Production Speeds — Automated Quality Assurance and NFC Validation for Zero-Defect Manufacturing.
Advanced 8K Secure Document Inspection System for Maximum Compliance & Security
The HyperVision 3500 sets a new industry benchmark in automated secure document inspection. Engineered specifically for secure credential manufacturing, including passports, national IDs, financial cards, and currency substrates, this advanced vision inspection platform combines 8K ultra-high-resolution optical systems, real-time embedded NFC/RFID chip validation, and fully integrated traceability.
Manufacturers gain unmatched quality control, compliance assurance, and productivity — achieving precision that manual inspection and current systems cannot match.
Passports and Laminations
Government-Issued IDs and Secure Credentials
Currency and Banknote
Enhanced Security & Regulatory Compliance
- Achieve 100% compliance with stringent global security regulations (ICAO, ISO, EMV)
- Real-time embedded chip validation to detect non-conforming units immediately
- Full data transparency with serialized, audit-ready inspection logs
Improved Production
Efficiency
- High-speed operation at 3,500 units per hour reduces inspection bottlenecks
- Automated defect detection drastically reduces manual oversight and rework
- Modular automation design enables easy scaling and integration with existing systems
Superior Quality & Product Integrity
- Detects micro-defects as small as 10 microns, far surpassing manual accuracy
- Ultrasonic sensors verify lamination bonding and thickness consistency
- Robotic handling ensures precise alignment and eliminates variability
- Multi-Layer High-Resolution Optical Inspection
- Real-Time NFC and RFID Chip Validation Module
- Delta-X Vision Intelligence for AI-Powered Defect Detection
- Ultrasonic Sensor Technology for Lamination Integrity
- Fully Robotic Material Handling and Automated Sorting
- Inline Print-and-Apply Labeling with Real-Time Serialization
- Modular Conveyor Layout for Flexible Integration
- End-to-End Data Tracking via Delta-X Tracker
- Inspection Resolution: Defects down to 10 microns
- Throughput Capacity: 3,500 units/hour (1 cycle per second)
- Optical Inspection: Dual-sided, multi-camera array
- Embedded Chip Validation: Live NFC & RFID testing
- Traceability Platform: Delta-X Tracker serialized logging
- Integration Capability: Compatible with ERP/MES systems
- Material Formats: Supports 182 × 405 mm and 186 × 264 mm substrates
- Regulatory Compliance: ICAO, ISO, EMV, and global security standards
Process Flow
The HyperVision 3500 automates every critical step in secure document inspection, providing unparalleled accuracy, reliability, and traceability from initial loading through to final sorting and labeling.
- Walking-Beam Stack Infeed: Efficient, continuous feeding of document stacks for uninterrupted throughput.
- Pick and Place Robots (Passport Covers): Precision handling and accurate positioning of passport covers to ensure inspection readiness.
- Pick and Place Robots (Separator Sheets): Automatic removal and management of separator sheets to reduce manual labor.
- Separator Sheet Outfeed: Efficient recycling and reuse of separator sheets, reducing waste and cost.
- Vacuum Conveyor Alignment: Secure, stable positioning of documents, maintaining precise alignment throughout inspection.
- Optical Alignment Sensors: Real-time monitoring and automatic adjustment to ensure exact document positioning prior to inspection.
- Teslin Side Vision Inspection: Multi-angle, ultra-high-resolution cameras detect scratches, delamination, bubbles, dents, and micro-contaminants.
- Ultrasonic Sensor Assembly: Accurately measures thickness, bonding consistency, and verifies lamination integrity.
- 3D Scanning for Delamination Detection: Advanced sensors quickly detect subtle internal defects, ensuring structural quality.
- Real-Time Defect Flagging: Immediate identification and logging of defects, linked directly to unique serialized product IDs.
- Delta-X Vision Intelligence: AI-powered inspection analysis to detect and classify defects with superior accuracy.
- Automated Defect Logging: Comprehensive, timestamped records generated and integrated instantly with Delta-X Tracker software.
- Automated Turnover Module: Precision reorientation of documents for thorough secondary inspection without compromising speed.
- Outer Surface Vision Inspection: Advanced camera arrays to detect print imperfections, surface scratches, and misalignment as small as 10 microns.
- Embedded NFC/RFID Chip Validation: Real-time resonance frequency and electrical validation, confirming chip performance and placement.
- Registration Mark Printing: Precision application of marks for accurate downstream alignment and traceability.
- AI-Enhanced Inspection Logic: Automatic detection and differentiation between critical and minor defects to prioritize sorting actions.
- Quality Factor Measurement: Ensures embedded chips meet rigorous standards for functionality and compliance.
- Automated Robotic Sorting: Intelligent sorting mechanism immediately diverts defective products for review or reprocessing.
- Stack Elevator Outfeed: Automatic stacking and transfer of approved products for organized, damage-free output.
- Outfeed Product Jogger: Ensures neat, precise alignment of documents, readying them for efficient downstream processes.
- OK/NOK Conveyor System: Clearly distinguishes compliant from non-compliant products, ensuring accuracy and reliability in sorting.
- Inline Print-and-Apply Labeling: Real-time, serialized labeling directly linked to unique inspection records for full traceability.
- Delta-X Tracker Integration: Seamless connectivity with ERP/MES systems, providing comprehensive auditability, real-time reporting, and end-to-end production transparency.
Included Technologies
The HyperVision 3500 incorporates advanced, integrated technologies designed to deliver unmatched precision, secure document inspection, comprehensive real-time traceability, automated defect detection, and NFC/RFID validation — ensuring 100% zero-defect compliance and optimal production efficiency.
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.
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: 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.
CASE STUDY
Pack-Smart Automates a High-Complexity Workflow with Breakthrough Efficiency Gains
Lindt, the iconic Swiss chocolatier known for its premium confections like Lindor truffles and Excellence bars, turned to Pack-Smart Inc. to overcome a critical production challenge. Faced with rising labor costs, inconsistent quality, and capacity limitations, Lindt sought an advanced packaging solution that could dramatically reduce manual labor while increasing precision, reliability, sustainability and output.
Pack-Smart Inc. delivered with the TF-500 Tray Forming & Fulfillment System, a high-speed automation system that reimagines the entire packaging workflow for simplex tray forming.
From 60 Hands to One Machine: The Future of Tray Forming is Here
This system not only delivered a 130% increase in productivity, but also transformed packaging from a production bottleneck into a scalable, strategic advantage.
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 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.
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.
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.