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.
HLB-500
High-Speed Carton
Labeling and Bundling
System
Automate end-of-line folded carton feeding, labeling, vision inspection, reject handling, counting, stacking, banding, and finished bundle delivery at speeds up to 25,000 cartons per hour. Reduce manual handling while maintaining control over label application, batch count, bundle formation, and production flow.
Control the End-of-Line Carton Handoff
High-output folding and gluing operations can produce cartons faster than manual teams can label, inspect, count, stack, and prepare them for downstream handling. When these steps remain disconnected, production capacity is lost at the end of the line through additional labour, inconsistent counts, unnecessary product handling, and delayed pack-out.
The HLB-500 Carton Labeling and Bundling System converts that handoff into one controlled production sequence. Folded cartons are fed short-edge leading, transported under vacuum, labeled, inspected, diverted when non-conforming, counted into defined stacks, banded, and delivered as finished bundles.
Servo-driven motion coordinates product position, label application, inspection timing, stack transfer, and bundle delivery. This protects end-of-line throughput while reducing repetitive handling and improving operator ergonomics.
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Pharmaceutical & Healthcare Cartons
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Retail-Ready Carton Bundles
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Personal Care & Cosmetics Cartons
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Food & Beverage Cartons
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Consumer Goods Cartons
Protect End-of-Line Throughput
- Top labeling output up to 25,000 cartons per hour
- Servo-synchronized feeding, conveying, labeling, and transfer
- Automated stacking and banding without interrupting carton flow
Reduce Manual Handling
- Automated carton counting, stacking, and bundle formation
- Recommended staffing of one to two people
- Ergonomic finished-bundle delivery for downstream handling
Improve Label & Bundle Control
- Vision inspection confirms label presence and placement
- Fiber-optic counting supports repeatable stack quantities
- Non-conforming cartons are diverted before stacking and banding
Watch the HLB-500 High-Speed Labeling
and Bundling System in Action
See how folded cartons move through feeding, vacuum transport, pressure-sensitive label application, vision inspection, reject handling,
batch counting, stacking, banding, and controlled bundle delivery.
- Automated short-edge-leading carton feeding
- Servo-driven vacuum transport for controlled product movement
- High-speed pressure-sensitive top label application
- Product-presence and label-presence sensing
- Adjustable brush pressure for consistent label adhesion
- Area scan vision inspection for label presence and placement
- Real-time divert and reject handling for non-conforming cartons
- Fail-safe reject confirmation through downstream sensing
- Fiber-optic batch counting for defined stack quantities
- Controlled indexing and stack transfer before banding
- Ultrasonic banding for paper or plastic band material
- Programmable band position through the operator interface
- Finished-bundle delivery with adjustable conveyor height
- Centralized servo motion control and touchscreen HMI
- Remote diagnostics capability
- Modular provisions for future printing, registration, curing, and personalization technologies
- Top labeling output: Up to 25,000 cartons per hour
- Label placement accuracy: ±0.76 mm at speeds up to 18,000 PPH
- Label placement accuracy: ±1.5 mm at speeds above 18,000 PPH
- Banding output: Up to 25 bundles per minute based on a 17-carton stack
- Maximum transport belt speed: 400 ft/min
- Recommended staffing: 1–2 people for operation, reloading, and delivery
- Target uptime: Greater than 95% under qualified production conditions
- Target reject rate: Less than 2% with prequalified materials
- Power requirement: 204–280 VAC, three-phase, 120 A
- Banding air requirement: 6 bar
- System performance remains dependent on approved materials, carton geometry, label format, stack quantity, and production conditions
Product Range
- Minimum product width: 50 mm
- Maximum product width: 140 mm
- Minimum product length: 100 mm
- Maximum product length: 225 mm
- Minimum product thickness: 0.5 mm
- Maximum product thickness: 5 mm
Self-Adhesive Label Range
- Minimum label width: 3.81 mm
- Minimum label length: 12.7 mm
- Maximum label width: 60 mm
- Maximum label length: 500 mm
- Maximum roll diameter: 560 mm on a 76 mm core
- Maximum roll width: 254 mm
Bundle and Banding Range
- Bundle stack height: 100–200 mm, product dependent
- Banding arch: 260 × 180 mm
- Band width: 30 mm
- Supported band materials: Paper and plastic
- Band position: Operator-adjustable through the HMI
System performance is product- and process-dependent and subject to material testing. Uptime and reject-rate targets exclude preventive maintenance, consumable changes, operator-related interruptions, and material issues.
Process Flow
Our customers consist of brand owners and industry leaders that continually come to us to overcome new complex engineering, manufacturing and distribution challenges. Find out more about the value and innovation we offer in each of these specific market segments.
- Carton Feeding
The FF-500 friction feeder separates folded cartons and introduces them into the line short-edge leading. The feeder is designed to handle a range of light and heavy flat materials while maintaining consistent spacing for downstream labeling and inspection.
- Vacuum Conveying
The VC-500 vacuum transport conveyor stabilizes each carton during acceleration and high-speed movement. Vacuum hold-down reduces slippage so label placement, inspection, and reject timing remain synchronized with the product position.
- Top Label Application
The HSL-60 applies pressure-sensitive labels to the top surface of each carton. Servo synchronization matches label dispensing to the incoming product, while an adjustable brush assembly applies controlled pressure to support label adhesion. - Label Verification
The VSC-1000 area scan vision system inspects each carton for label presence and placement. The platform can also support future OCR and barcode inspection capabilities when configured and licensed for those applications.
- Divert and Reject
The DV-500 divert module removes cartons that fail the configured inspection criteria. Reject confirmation sensors verify that the identified carton has been removed before conforming products continue toward stacking and banding.
- Carton Transfer
The TR-250 transfer module manages the handoff from the inspection section to the stacking section. Controlled indexing maintains carton orientation and positions each product for accurate batch formation. - Batch Counting and Stacking
Fiber-optic sensors count cartons according to the selected production recipe. Each carton is deposited into the stacking unit until the required batch quantity has been reached.
- Stack Indexing
The completed stack is indexed into controlled divisions before transfer to the banding unit. Product-contact components are selected to reduce marking or damage during high-speed handling.
- Band Application
The BA-2000 banding unit receives the completed stack and applies a 30 mm paper or plastic band. Operators can define the band position through the HMI to support different carton and bundle formats.
- Finished Bundle Delivery
The DL-500 delivery conveyor receives the completed bundle and moves it into the operator handling area. Adjustable conveyor height and controlled bundle spacing support safer, more ergonomic pack-out.
Included Technologies
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
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.
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.
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.
