System Performance

• Complete-system throughput: Up to 7,000 mounted sheets per hour
• Flexographic pattern-gluing capability: Up to 300 m/min
• Documented glue-pattern placement: ±2 mm
• Documented sheet-to-sheet mounting accuracy: ±2 mm
• Qualified uptime target: 90% under approved FAT/SAT conditions
• Qualified reject-rate target: Less than 1% under approved FAT/SAT conditions
• Base-sheet and mounting-sheet operation: Automated
• Finished delivery: Vertical stacked output
• Production performance is subject to material testing and application qualification

Validated Sheet Configuration

• Front sheet: 530 × 750 mm
• Back sheet: 530 × 750 mm
• Validated material: 12-point C1S
• Minimum product length in travel direction: 11 inches
• Sheet loading: Up to 15-inch-high feeder magazines
• Additional materials, calipers, coatings, and sheet formats require application testing

Pattern Gluing

• Application method: Flexographic pattern gluing
• Repeat lengths: 6, 12, 24, or 36 inches
• Pattern generation: Application-specific photopolymer plate
• Glue metering: Precision-ground anilox cylinder
• Doctor roller: Motorized
• Glue-position adjustment: Horizontal and on the fly
• Missing-product detection: Supported
• Selective application: Supported
• Documented adhesive type: Cold fusion glue
• Other adhesives and coatings: Subject to qualification

Electrical Requirements

• Base-Sheet Feeding
  The FF-800 friction feeder separates the base sheets and introduces them into the production sequence. High-capacity magazines support sustained production while reducing the frequency of manual sheet replenishment.
  
• Vacuum Transport
  The VC-800 vacuum conveyor stabilizes each registered sheet during transfer. Vacuum hold-down limits sheet lift, movement, and skew as the product moves toward inspection and adhesive application.

• Lugged Registration
  The LC-800 lugged registration conveyor establishes the sheet’s leading-edge position and travel alignment. This creates a controlled positional reference for barcode inspection, pattern gluing, and secondary-sheet mounting.

• Barcode Inspection
  The incoming sheet passes through an in-line barcode inspection point. The system confirms product identity or version against the active production recipe before adhesive is applied. Incorrect or unreadable product data can trigger an exception before the sheet proceeds deeper into the mounting process.
  
• Flexographic Pattern Gluing
  The FPG800 applies cold glue to defined areas of the base sheet. A precision-ground anilox cylinder meters the adhesive, while the application-specific photopolymer plate transfers the required pattern. This allows glue to be placed around windows, perforations, removable areas, or other product features without coating the entire sheet.

• Pattern Position Control
  Servo registration coordinates the application cylinder with the moving sheet. Operators can adjust pattern position during production, while missing-product detection prevents glue application when a valid sheet is not present.

• Secondary-Sheet Feeding
  The SF-800 smart feeder independently introduces the front or mounting sheet. Separate feeding allows both sheet streams to be controlled before they are combined.
  
• Automated Sheet Alignment
  The automated alignment module registers the secondary sheet relative to the glued base sheet. Controlled motion establishes the sheet-to-sheet position before physical contact.
  

• Sheet Mounting
  The aligned secondary sheet is placed onto the adhesive pattern while the base sheet remains under controlled transport. This creates a mounted sheet product without requiring a separate offline assembly process.
  
• Mounted-Sheet Vacuum Transfer
  The combined product transfers under vacuum toward compression. Controlled transport helps preserve sheet alignment before the adhesive bond has been fully consolidated.

• Compression
  The mounted sheets pass through the compression module, where controlled pressure promotes adhesive transfer and contact across the required bonding areas.
  
• Divert and Reject
  Products that fail barcode, placement, or other configured inspection criteria are removed by the divert module. Reject handling prevents non-conforming mounted sheets from entering the accepted finished stack.
  

• Placement Verification
  An in-line vision inspection system checks the position of the mounted sheet against the configured tolerance. This provides line-level verification that the two sheets were aligned and affixed as intended.
  
• Vertical Stack Delivery
  Conforming sheets are collected by the AS-1100 sheet stacker. Controlled stacked delivery prepares the output for pallet handling or downstream operations such as kiss cutting, perforating, separating, shingling, finishing, or packaging.

• High-speed vibratory bowl for efficient product sorting
  
• Dual buffering system to accommodate high throughput
  
• Advanced rotary pick and place system for precise product placement

• Vacuum-assisted horizontal tracks for smooth control and transfer
  
• Lugged horizontal track to maintain product orientation and spacing
  
• Integrated control system with HMI10 for easy operation

• Speed: Up to 200 3D products per minute
  
• Product Size Range: 10 × 10 mm to 50 × 50 mm
  
• Material Handling: Capable of processing various materials from lightweight to heavy stock

• Feed Method: Vacuum nests rotary head with fiber-optic sensing
  
• Power Requirements: 230 V AC, 3 phase, max 30 A

• VF900 Vibratory Bowl Feeder: Sorts and aligns products for further processing.

• Vacuum Driven Horizontal Track: Transfers aligned products toward the placement station.

• 3D50 3D Object Feeder: Accurately picks and places products onto the next stage of the production line with precise control.

• 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

• 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