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.
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 plastic 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.