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
-
Rigid Luxury Trays
-
Food and Beverage
-
Personal Care & Cosmetics
-
Multi-Compartment Trays
-
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.
CC-500
Carton Check and Defect
Detection System
Elevate your production quality with the CC-500, a cutting-edge defect detection system designed to ensure flawless carton output through comprehensive inspection.
Ultimate Precision in Print Quality Assurance
The CC-500 delivers unparalleled defect detection for cartons by integrating advanced imaging and processing technology to inspect a variety of materials at speeds up to 150 meters per minute.
This system is adept at identifying a wide range of print defects and substrate inconsistencies, ensuring that only perfect cartons reach your customers.
Folding Cartons
Paper & Corrugated Material
Quality Control
- Ensures 100% inspection of print, embossing, and foil on each carton, significantly reducing the risk of customer rejections.
- Advanced defect classification and real-time alerts allow for immediate correction, minimizing waste.
- Integrates seamlessly with existing production lines, enhancing overall efficiency without compromising on throughput.
Operator Efficiency
- User-friendly interface and automated setup reduce operator workload and training time.
- Real-time data and image capture of defects enhance operator decision-making.
- Customizable reports and analytics support continuous improvement and operational oversight.
Driven Reliability
- High-resolution line scan cameras combined with LED illumination capture minute defects in real time.
- Flexible system configuration accommodates a range of substrate types and sizes.
- Robust data management tools ensure traceability and consistency across production batches.
Watch the CC-500 in Action
- High-Resolution Inspection Cameras: Deploy the latest line scan technology for sharp imaging and accurate defect detection.
- Automated Defect Classification and Response: Sophisticated software algorithms classify defects and automatically guide response actions, such as ejecting defective sheets.
- Flexible Material Handling: Accommodates various materials, including paper, paperboard, plastic, and foils, ensuring versatility across packaging applications.
- Advanced Reporting Capabilities: Generates detailed defect reports and integrates with enterprise systems for comprehensive quality management.
- Robust System Integration: Seamlessly connects with in-line equipment like roll splicers and foil stampers, creating a unified production flow.
- Customizable Inspection Sensitivity: Settings can be adjusted for different products or customer requirements, ensuring tailored inspection processes.
- Max Speed: 150 m/min for continuous inspection
- Material Width: Up to 250 mm
- Inspection Accuracy: Detects defects as small as 0.18 mm
- System Flexibility: Supports integration with multiple camera views for comprehensive coverage
- Connectivity: Includes options for network integration and remote diagnostics
Process Flow
The CC-500 Compact Carton Former revolutionizes the way retail-ready packaging is produced by integrating a seamless process flow that ensures efficiency and consistency.
- SF500 Smart Feeder: Utilizes high-performance brushless servo motors managed by a leading-edge motion controller, enabling precise product feeding at high speeds. This feeder is designed for continuous operation and supports quick setup changes through its user-friendly touchscreen interface.
- VC500-12 Vacuum Conveyor: Ensures stable and secure transportation of materials through the inspection zone with an advanced vacuum system that adjusts to accommodate different substrate thicknesses and widths.
- Vision Camera Inspection System: Employs state-of-the-art high-resolution line scan cameras to capture detailed images of each carton. This system uses advanced image processing algorithms to detect a wide range of defects, such as color deviation, streaks, and misregistration.
- LED Illumination System: Provides optimal lighting conditions for the inspection cameras, enhancing defect detection by improving contrast and clarity in the captured images.
- Delta-X Tracker: Acts as the central data management system, logging all detected defects and managing quality control processes. It provides real-time feedback and detailed reports, helping to ensure consistent product quality and enabling quick response to any issues.
- SQL Database Integration: All inspection data, including images and defect classifications, are stored in an SQL database, allowing for easy retrieval and analysis. This system supports historical data analysis and real-time
decision-making.
- Emerald 2500 Configurable System Motion Controller: Controls the entire inspection system, ensuring synchronized operation between feeding, inspection, and output. It facilitates the integration of the CC-500 with existing production lines, maintaining high throughput and operational efficiency.
- HMI10 Human Machine Interface: Provides an intuitive user interface for system operators, allowing easy control over the inspection process and quick access to system settings and diagnostics. It supports multi-language functionality and is designed for ease of use to minimize operator training requirements.
Included Technologies
The
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-500
Specialty Carton Folding
and Finishing
Automated Kitting, Carton Folding, Sealing and DOD Personalization. Master the art of folding and gluing with the FG-500, engineered for versatility and efficiency in diverse production environments.
Streamline Your Production with Advanced Folding and Gluing
The FG-500 system expertly coordinates carton kitting, gluing, folding, and personalization processes to deliver precision and efficiency in packaging operations. This robust system features inline high-accuracy affixing with a precision of ±0.4 mm and advanced 600 DPI printing capabilities, complemented by comprehensive quality assurance measures.
At the outset, all components are meticulously affixed to a flat carton carrier using fugitive glue. This prepares the carton for the application of secure glue, essential for robust packaging, followed by precise folding and compression of the front, back, and sides to form a securely sealed package.
Direct to Consumer Products
Sample Packs
Auto-Erect Cartons
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.
FG-1500
Specialty Corrugated
Folding and Finishing
Specialty 60″ Corrugated Folder Gluer with Plastics Clips and Reinforcements for POP Displays.
Specialty Folder Gluer with High Speeds and Quick Changeovers
FG-1500 specialty folder gluer series are built to enable the production of unconventional and complex products based on corrugated materials fitted with add-ons such as clips, windows, RFIDs, labels, and reinforcement inserts. FG series specialty folder gluers process E, B, C flute and double wall corrugated board with 60″ maximum blank width.
System utilizes a pick and place insert attachment, standard straight line and auto bottom functions, pre-fold and final fold sections, independently driven upper carriers with an extended final fold. Like all Pack-Smart high-performance finishing systems, the FG series are operator friendly with world-class reliability and unmatched flexibility.
POP Displays (Small)
POP Displays (Medium)
POP Displays (Large)
Advanced Capabilities
- Specifically built for unconventional and intricate products based on corrugated materials, ensuring versatility in production.
- Processes E, B, C flute and double-wall corrugated board, accommodating a wide range of packaging needs.
- Seamlessly integrates clips, windows, RFIDs, labels, and reinforcement inserts, enhancing product value and functionality.
- Ideal for creating a 60″ corrugated folder gluer with plastic clips and reinforcements, especially for POP displays.
Precision & Efficiency
- Achieves speeds of up to 2,500 PPH, optimizing production timelines.
- Ensures plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm, guaranteeing product consistency.
- Maintains front-to-back and side-to-side sheet registration within ±0.5 mm, ensuring precise alignment and folding.
- Accommodates a wide range of blank sizes, from a minimum of 4″ width and 5″ length to a maximum of 60″ width and length.
User-Friendly & Modular
- Designed with the user in mind, ensuring ease of operation and minimal training requirements.
- Allows for the addition or removal of modules as needed, adapting to evolving product requirements effortlessly.
- 100% servo-driven with digital brushless servo motors, ensuring smooth operations and reduced maintenance.
- Recommended operation with one main operator, one person for reloading, and one person on delivery, optimizing workflow and productivity.
Watch the Specialty Corrugated Folding and Finishing in Action
- Specialty Folder Gluer Design: Built specifically for unconventional and intricate products based on corrugated materials.
- Diverse Material Handling: Capable of processing E, B, C flute, and double-wall corrugated board.
- Integrated Add-Ons: Seamlessly integrates with clips, windows, RFIDs, labels, and reinforcement inserts.
- High-Speed Operations: Achieves speeds of up to 2,500 PPH.
- Accurate Affixing: Ensures plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm.
- Sheet Registration: Maintains front-to-back and side-to-side sheet registration within ±0.5 mm.
- Modular Flexibility: Allows for the addition or removal of modules as needed.
- State-of-the-Art Technology: 100% servo-driven with digital brushless servo motors.
- Advanced Diagnostics: Integrated with a virtual machine platform for system diagnostics.
- Speed: Up to 2,500 PPH
- Affixing Accuracy: Plastic clips, rigid window, and reinforcement affixing accuracy within ±0.5 mm
- Sheet Registration: Front-to-back and side-to-side sheet registration within ±0.5 mm
- Minimum Blank Size: Width 4”, length 5”, thickness 0.4 mm
- Maximum Blank Size: Width 60”, length 60”, thickness 6 mm
- Labor Requirements: 1 operator + 1 person reloading + 1 person on delivery
- Technological Integration: Virtual machine platform system diagnostics
- Drive System: 100% servo driven with digital brushless servo motors
Process Flow
This workflow outlines each critical stage of the corrugated folding and gluing process, meticulously designed to ensure efficiency, precision, and quality from start to finish. Follow the path from material intake to final product assembly, experiencing how integrated technologies streamline operations and elevate output.
- High-Speed Auto Feeder: Handles a broad range of materials with consistency at speeds up to 500 sheets per minute, ensuring smooth and continuous operation. Features advanced sensors and servo-driven mechanisms that adjust automatically to material thickness and size.
- Precision Placement System: Delivers materials with an exact placement accuracy of ±0.5 mm, essential for subsequent processing steps. Utilizes precision vacuum conveyors and robotic placement arms to handle materials gently and accurately.
- Cold Glue Applicator: Dispenses cold glue with pinpoint accuracy, ensuring strong, permanent bonds.
- Front and Back Fold Units: Provide versatile folding capabilities, including complex right-angle and longitudinal folds.
- Hot Melt Applicator: Applies hot melt adhesive for quick-setting, durable seals appropriate for a variety of materials.
- Plow Fold Technology: Executes high-speed inline folding, suitable for a range of production demands from simple to complex configurations.
- Sequential Lug Conveyor: Provides accurate product registration with adjustable intervals, facilitating synchronized operations in assembly lines. Features modular sections that can be configured for various product sizes, enhancing flexibility.
- Integrated Vacuum Conveyor System: Ensures precise control over product movement and placement, critical for high-speed assembly and kitting. Equipped with multiple vacuum zones that are selectively activated to handle different products securely.
- Emerald 2500 Control System
- HMI Human Machine Interface
Included FG-1500 Technologies
Each component is strategically integrated to enhance performance and reliability throughout the folding and gluing process. These technologies, from advanced feeding mechanisms to sophisticated software systems, represent the pinnacle of innovation, ensuring that every product meets the high standards of durability and design excellence expected in today’s competitive markets.
FF Series
Primary Friction Feeder
The FF Series Friction Feeder can handle the lightest paper and is equally at home when dealing with heavy stock materials when called upon.
HM-10
Hot Melt Glue System
Revolutionize your production with the HM-10 Hot Melt Glue System, offering precision application for a wide range of adhesive needs.
CEG-1
Cold Glue System
The CEG-1 Cold Glue System is engineered for high-precision, tamper-proof adhesive applications.
RPP Series
Reciprocating Pick and Place Series
Maximize your production efficiency with the RPP Series, designed for high-speed, accurate handling of delicate materials and uniquely shaped products.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
PF50-90
Plow Fold Module
The PF50-90 Plow Fold Module integrates seamlessly into production lines, offering both left and right folding configurations.
SF Series
Secondary Friction Feeder
Reaching up to 600 products per minute, the SF Series is a perfect choice for handling light paper to heavy stock material.
HLA-500
High-Speed Pressure Sensitive
Label Application System
This 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 Print Finishing with Quick Job Changes
Pack-Smart’s HLA-500 system is the fastest solution for accurate velcro label and hi/low tack tape application at speeds up to 15,000 products per hour. Because of a modular system approach, HLA-500 is ideally suited to simultaneously carry out other in-line processes such as folding and gluing, creasing, tipping, Braille embossing inspection and digital imaging.
The system comes with your choice of delivery options, shingled, in batches, or bridging modules, for seamless integration with third-party equipment for downstream processes.
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.
WA-800r
Window Affixing
System
WA-800r delivers unmatched speed, accuracy and flexibility allowing affixing of rigid windows to virtually any carton product available.
Rigid Window Affixing for Specialty Packaging
WA-800r Rigid Window Affixing System is the fastest machine on the market, producing rigid window cartons for any market that incorporates high visibility packaging at low ‘per-unit’ costs and speeds up to 25,000 products per hour.
Due to our modular system approach, it is ideally suited to simultaneously carry out other in-line processes such as folding and gluing, creasing, tipping, braille inspection and digital imaging.
High Value Cartons
Specialty Packaging
Flexibility & Creativity
- Affix rigid windows to a diverse range of carton products, from compact cosmetic cartons to expansive liquor boxes.
- Harness the power of the fastest machine on the market, producing high-visibility packaging at economical ‘per-unit’ costs.
- Dive into a world where creativity meets reality, crafting unique packaging designs tailored to specific market needs.
Precision at Its Best
- Affix a myriad of windowed substrates, including PVC, PET, PLA, polystyrene, and more, with single-stream capabilities reaching up to 25,000 products per hour.
- Achieve impeccable window placement accuracy of ±0.02″, ensuring each product stands out with its visual appeal.
- Trust in Pack-Smart’s commitment to precision, where speed and accuracy go hand in hand, delivering top-notch results every time.
Comprehensive Modular Efficiency
- Experience the power of a modular system, adept at performing multiple in-line processes simultaneously, from folding and gluing to creasing, tipping, and digital imaging.
- Seamlessly integrates with almost any folder gluer, thanks to the system’s versatile delivery options and bridging modules.
- Leverage Pack-Smart’s modular design focus, ensuring all essential processes are completed in a single system pass, including folding, gluing, scoring, tipping, personalization, and more.
Watch the Window Affixing System in Action
- Affix rigid windows to a vast array of carton products, from small cosmetic cartons to large liquor boxes.
- Suitable for high-visibility packaging across various markets.
- Single stream capabilities reach up to 25,000 products per hour.
- Affix a variety of windowed substrates, including PVC, PET, PLA, polystyrene, and more.
- 7” Color Human Machine Interface equipped with a product recipe function.
- Extensive diagnostics and job/parameter storage through the recipe function.
- Simultaneous execution of multiple in-line processes such as folding, gluing, creasing, tipping, Braille inspection, and digital imaging.
- Integration capabilities with almost any folder gluer through delivery options or bridging modules.
- Window placement accuracy of ±0.02″.
- Ensures visually appealing products without compromising on speed.
- Ethernet and internet connectivity via laptop connection.
- Real-time tracking and reporting with OEE (Overall Equipment Effectiveness) above 90%.
- Networked brushless servo-driven technology for the timed blank feeder.
- Flexi servo-driven gluing module with hard anodized, deep etched metering cylinder.
- On-the-fly adjustments for both glue-to-carton registration and cylinder-to-carton for glue and window fine-tuning.
- High-speed belt lifting system with automatic speed compensation.
- Stainless Steel Planetary gearheads.
- Fibre-optic networked control systems.
- Variable speed delivery system with batching.
- Minimum — 2″ × 2″ × 0.003, maximum — 24″ × 12″ × 0.01″.
Process Flow
The process flow for the WA-800r Rigid Window Affixing System is meticulously designed to ensure precise, secure, and efficient affixing of rigid windows to various packaging types. This system integrates each step, from initial material feeding to final quality inspection, ensuring high-speed, accurate application with robust security measures.
- Friction Feeder: The feeders are notably rugged paper feeding systems, and the solid steel construction ensures stability and high performance even in the toughest environments, resulting in speeds of up to 600 products per minute.
- Vacuum-Assisted Placement: The vacuum-assisted system securely holds the windows during the affixing process, providing stability and precision. This feature ensures that the windows are affixed without movement, resulting in a clean and accurate application.
- Hot Glue Application: For applications requiring strong and permanent adhesion, the hot glue system dispenses hot extruded glue. This versatile feature accommodates a range of packaging needs, from secure sealing to easy peel-off labels.
- Lugged Registration: The purpose of the alignment conveyor is to accurately space the carrier and align it exactly, one at a time, then feed the carrier onto the vacuum conveyor. The alignment conveyor is comprised of chain-driven lugs and side guides. The side guides are manually adjustable as are the lugs to allow for different sizes of material. This conveyor acts as the master for the speed control when in a fully automatic mode of operation. Most of the other sections of machinery synchronize to this speed.
- Cold Glue Application: The cold glue system automatically dispenses cold extruded glue for secure and tamper-proof sealing of rigid windows. This ensures that the windows are firmly affixed to the packaging, providing durability and security.
- Vacuum Transport: The Vacuum Conveyor is a truly versatile servo-driven transport module designed to maximize throughput with high acceleration up to speeds of 600 ft/min. Perforated PVC belts with vacuum suction offer slippage-free transport of cards and paper products with conveyor widths ranging from 8 to 60 inches. Powder-coated adjustable steel frame with anodized aluminium dual T-slots allows for seamless integration with existing modules, making it ideal for all custom tipping, converting, or finishing applications.
- Rotary Pick & Place: The rotary RP series feeders feature 360° rotating arms with articulating suction cups, enabling millisecond product attach and release for high-speed feeding. The highly adjustable modular components enable handling of varying product sizes and adjustable pick-up and drop-off points with quick changeovers. Products such as cards, leaflets, sachets, rigid windows, and DVDs which are a challenge for typical belt-driven feeders, are a natural fit for the RP series rotary pick and place feeder.
- Divert Gate: 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.
- Integrated Inspection Cameras: The integrated inspection cameras provide detailed imaging of the affixed windows, allowing for precise quality checks. This feature ensures that any imperfections are detected early, maintaining the high standards of the final product.
- Delivery Transport: 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 the need for counting finished product while increasing productivity. Four-inch locking casters are a standard feature of DL 500, providing outstanding mobility.
- Emerald 2500: CAMS epitomizes our expertise in integrating standardized modular technologies into fully automated, high-performance, flexible lines. We offer options that meet production requirements, whether automating product handling to control a single module or automating a complete line with primary and secondary packaging operations.
- HMI-10: Graphic HMI connects the operator with the machine. Pack-Smart HMI combines a PLC and HMI into one unit. Utilized worldwide to employ diverse applications, feature options include touchscreen and function key models, serial and Ethernet communication. This graphic HMI provides an excellent combination of display and control in a single, easy-to-use package.
Included Technologies
The WA-800r Rigid Window Affixing System incorporates state-of-the-art technologies to enhance its performance and reliability. Key technologies include advanced feeding mechanisms for consistent material handling, precision window placement technology for accurate affixing, and real-time monitoring systems to ensure quality and efficiency throughout the process.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
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.
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.
PG-900
Flexo Pattern Glue Module
Elevate your production capabilities with the PG-900 Flexo Pattern Glue Module, designed for precise and flexible adhesive 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.
DL Series
Shingled Delivery Transport
Discover the DL Series Shingled Delivery Transport, designed for efficient and ergonomic conveying of diverse printed materials.
FG-800
Reinforced Carton
Specialty Finishing
Combine folding, gluing, affixing, personalization, and sorting in a single pass.
High Speed with Quick Changeovers
The FG-800 is designed to give the tools and flexibility needed to explore new manufacturing opportunities in the folding carton and specialty finishing world. The alignment of cartons is handled by a state-of-the-art registration module, which employs innovative servo technology making setups swift and effortless.
High Value Carton
Auto-Erect Cartons
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 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 Rigid Window Affixing System is designed to ensure precise, secure, and efficient production of folding cartons. This system integrates each step, from initial material feeding and registration to final gluing and finishing, ensuring high-speed, accurate application with robust security measures.
- Friction Feeder: The FG-800 utilizes the FF1500 Friction Feeder, which ensures consistent and reliable feeding of corrugated blanks into the system. This feeder is designed to handle a variety of materials, maintaining high speeds and precision.
- Registration Module: The registration module aligns the material positioning and spacing between incoming blanks, ensuring accurate processing throughout the production line.
- Friction Feeder: FF Series friction feeders are designed with a solid steel construction to ensure stability and high performance even in the toughest environments, resulting in high production speeds of up to 600 PPH.
- Hot Glue System: The HM10 Hot Melt Secure Glue System applies hot glue for tamper-resistant and secure enclosure gluing. This system ensures a strong bond that is essential for high-security applications.
- Rotary Pick and Place Feeder: Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
- Cold Glue System: The CEG1 Cold Extruded Glue System applies cold glue, providing a tamper-evident seal. This system is ideal for applications requiring high levels of security and precision.
- Plow Fold Module: The PF50-90 Plow Fold Module can fold sheets and booklets at high speeds, accommodating both left and right folds. It is versatile, allowing for tool-less adjustments to meet various folding requirements.
- Vacuum Transport: The VC1500-12 Vacuum Transport module provides smooth and efficient variable speed transport for the host blanks, ensuring that materials move through the system without disruption.
- Front Fold Module: The MFF120 Front Fold Module ensures precise folding of materials, using air jets and hooked arms to achieve accurate folds. This module is essential for creating high-quality finished products.
- Extended Compression: This feature ensures that the glue is fully cured at speeds 10 times faster than legacy pressure seal technology, enhancing the strength and durability of the final product.
- Delta-X Data Management Platform: The Delta-X software provides real-time tracking, configurable workflows, and batch processing. This system ensures that all production data is accurately tracked and managed, enhancing overall operational efficiency.
- HMI-10 Interface: The HMI-10 graphic interface connects operators with the machine, combining a PLC and HMI into one unit. This interface offers intuitive controls and real-time data, facilitating easy operation and management of the FG-800 system.
Included Technologies
The FG-800 Rigid Window Affixing System incorporates advanced technologies to enhance its performance and reliability. Key technologies include high-speed friction feeders, precision affixing mechanisms, advanced folding modules, and real-time data management systems. These technologies work together to ensure consistent, high-quality production of folding cartons.
RP Series
Rotary Pick and Place Series
Consistently feed, insert, attach, and batch delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
FF Series
Primary Friction Feeder
The FF Series Friction Feeder can handle the lightest paper and is equally at home when dealing with heavy stock materials when called upon.
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.