Duplex Card
Personalization
System 

High-Speed Performance

• Industry-leading speeds of up to 30,000 PPH
• Optimized end-to-end solutions, including batching, wrapping, and labelling bundles

Integrated Verification Systems

• Consistent quality checks throughout the production process
• Automated error detection and diversion to ensure product accuracy
• Remake initiation for guaranteed 100% verified products

Comprehensive Software & Hardware Platform

• Powered by Pack-Smart Inc.’s robust virtual machine software/hardware platform
• Rugged fiber-optic network ensures reliable data transfer and processing
• Customizable report compliance interface for tailored data insights

Versatile Card Handling

• Efficient management of diverse card formats, including CR80s, M6 hang tags, and custom-shaped cards
• Personalization features such as magstripe label affixing, 1D and 2D barcode printing, and scratch-off label application

Modular & Adaptable Design

• Tailored solutions to meet specific production needs
• Future-proof design allows for system customization and integration of new features

• Speed: Up to 30,000 UPH
• Personalization: Magstripe label affixing, 1D and 2D barcode printing, scratch-off label application

• Card Formats Supported: CR80s, M6 hang tags, and many custom-shaped cards
• Verification: Integrated systems for product tracking and error detection

• Feeding, Registration and Alignment: Rotary Pick and Place Feeder consistently feeds, inserts, attaches, and batches delicate materials and oddly shaped products at 30,000 PPH, with vacuum pick & place motion and ±0.02″ placement accuracy.
  
• Smart Chip Encoding: Pack-Smart’s SCE-1 Smart Card Encoding module is designed to provide a versatile drop-in enhancement for CP-250 systems to benefit from expanded EMV and contact/contactless card encoding capabilities. The high-speed encode module combined with pogo pin contact interface allows easy integration with customers’ existing infrastructure and provides a solid return on investment. 
  
• Magnetic Strip Encoding: High-speed and modular magnetic encoding solution designed with advanced and industrial-grade electronics and integrated magnetic stripe encoding software. Module supports encoding magnetic stripes from top and bottom. System can be configured with two or three-track read and write heads, providing reliable magnetic stripe encoding capabilities. Card personalization of products of any size and shape in compliance with ISO standards.

• DOD Variable Print: Smart Jet uses industry-leading head technology to deliver UV-cured 600 DPI DOD Ink onto any surface at speeds over 500 feet per minute. Up to 8 heads can be combined to reach widths of 575 mm for full web or press sheet personalization.
  
• UV Drying: The UVL features a high-power LED UV lamp intended for high-speed, single-pass drying or curing applications. The air-cooled LED lamp allows for an 85% increase in energy consumption as compared to traditional, long lifecycle, easy setup, and minimal maintenance for a high-efficiency process compared to typical arc or microwave technologies. The UVL reduces wear on conveyor belts and enables compatibility with heat-sensitive substrates.

• Label Application: High-Speed Label Applicator is an asset in any demanding manufacturing environment. With the ability to apply all varieties of pressure-sensitive labels at line speeds up to 200 m/min (660 ft/min), the HSL-60 can apply 400 labels per minute, with a best-in-class placement accuracy of ±0.4 mm. Depending on material and label size, Pack-Smart HSL-60 Labeller will accurately apply labels to any product in line with any printing, converting and packaging production lines. When operating in a “Zero Downtime“ configuration, the HSL-60 tandem system allows for safe “on the fly” roll changes eliminating downtime required for roll changes.

• Inspection, Verification & Placement Inspection: Area Scan Vision will inspect variable OCR, barcode, and ANSI verification, as well as perform print and placement quality checks. The native 64-bit environment alongside the Xenon processors allows image processing as fast as 120 FPS.

• Divert & Rejection: 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.

• Product Delivery: 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 needs for counting finished product, while increasing productivity. Four-inch locking casters are a standard feature of DL 500 providing outstanding mobility.

• 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 the limit for sequential errors on sensors/data acquisition units checking the product status. The tracking system will trigger a fault when a maximum allowed consecutive errors occur.