Card to Bundle
in One Pass

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

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

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

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

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

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

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

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

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

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

General

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

Data Integrity

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

Batching

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

Data Mapping & Integration

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

Product Registration

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