3DF-1

3D Product Feeding
System

Revolutionize your production line with the 3DF-1, designed to sort, orient, and affix loose 3D products with unparalleled speed and precision.

3D Product Feeding System

Care-Free Bulk Loading

Redundant Feed Channels

Up to 200 3D PPM

3DF-1 uses a high speed vibratory bowl to handle delicate format 3D products. Once the parts are sorted and correctly oriented, they are transfered to a redundant set of buffers.

These buffered parts are then transfered to lugged horizontal track which allows smooth control of the products at the same time meeting the feeding request of the line. A precise rotary motion pick and place system will deliver them from the lugs to the packaging line.

Fast Moving Consumer Goods

Pharmaceutical Products

  • Eliminates the need for manual sorting and placement
  • Decreases staffing requirements, reducing labor costs
  • Enhances workplace safety by minimizing human interaction with machinery
  • Handles up to 200 products per minute, maximizing productivity.
  • Maintains consistent operation even under high-demand conditions.
  • Reduces bottlenecks in the production line, ensuring a smooth flow.
  • Care-free bulk loading reduces downtime and increases operational reliability.
  • Redundant feed channels ensure there is no interruption in the feeding process.
  • Precision handling of 3D products prevents damage and improves quality control.
 
  • 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

The 3DF-1 operates within a highly structured process flow designed to maximize both precision and efficiency in 3-dimensional product feeding. Starting with the automated feeding of items into the system, each component is carefully aligned and transported through various stages of handling and assembly.

  • 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.

Utilizes a high-speed vibratory bowl combined with a vacuum-assisted rotary head for precise product handling and placement. This system ensures gentle handling of 3D products, reducing waste and increasing efficiency. The integrated fiber-optic sensing guarantees exact product positioning, enhancing the overall precision of the production process.

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.

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. 

FG-500

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.

12,000

Units per Hour

±0.4 mm

Affixing Accuracy

600 DPI

Printing Capabilities

Direct-on-Demand

Barcode Printing

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

  • Adapts to different materials and designs.
  • Accommodates varied production demands.
  • Allows for quick setup changes between jobs.
  • High throughput for increased productivity.
  • Consistent quality reduces waste.
  • Streamlined processes cut down production time.
  • Quick setup and easy maintenance.
  • Reliable operation with minimal interruptions.
  • Designed for easy access to components for rapid servicing.
 
  • 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.

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.

      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 60″ Corrugated Folder Gluer with Plastics Clips and Reinforcements for POP Displays.

      Up-to 2,500

      Products per Hour

      60″ Cartons

      Max Length

      ±0.5 mm

      Affixing Accuracy

      32″

      Max Clip Length

      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)

      • 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. 
      • 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.
      • 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.
       
      • 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

      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

          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.