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.
WP-360
Web Digital Printing, Inspection
and Tracking System
Revolutionize your label and flexible packaging production with the WP-360, offering unmatched speed and precision in web digital printing, inspection, and tracking.
Precision Web Printing and Quality Control
The WP-360 is a state-of-the-art web personalizing system that integrates advanced digital printing with comprehensive inspection and tracking.
Capable of handling speeds up to 500 feet per minute, this system uses UV cured ink to adhere to any surface, ensuring high-quality print on diverse substrates.
The integrated high-resolution line scan camera and Delta-X tracking system ensure flawless production by identifying and addressing defects in real time.
Pressure Sensitive Labels
Flexographic Narrow Web
High Efficiency Output
- Achieves over 1,000,000 labels per liter of ink, significantly reducing consumable costs.
- Delivers perfect first prints consistently, minimizing waste and rework.
- Operates at speeds of up to 500 feet per minute, boosting productivity.
Advanced Quality Control
- Incorporates camera-based aggregation and verification by weight to ensure each label meets strict quality standards.
- Automated bundle labeling streamlines the finishing process, enhancing throughput.
- Quality assurance station detects and removes or flags defective products on-the-fly, maintaining product integrity.
Superior Print Capabilities
- Utilizes UV ink that adheres to any substrate, expanding application possibilities.
- Supports a full web width of 14.3 inches, maximizing print area for large format applications.
- Extremely low ink consumption paired with high-resolution printing reduces operating costs while maintaining environmental sustainability.
Watch the WP-360 in Action
- Advanced UV Digital Printing: Utilizes state-of-the-art UV ink technology that adheres to any surface, including non-porous materials, ensuring versatile application across different substrates.
- High-Resolution Printing: Offers a maximum resolution of 600 DPI, providing fine detail and sharp images, ideal for complex graphics and high-quality labeling requirements.
- Full Web Print Area: Features a full 14.3-inch print width, allowing for large format printing and efficient use of media, reducing waste and increasing productivity.
- Extremely Low Ink Consumption: Designed for efficiency, the system uses UV ink sparingly without compromising print quality, significantly lowering operating costs over time.
- Integrated Inspection System: Equipped with a high-resolution line scan camera that continuously inspects the print for defects, ensuring only the highest quality products are produced.
- Real-Time Tracking and Defect Management: Incorporates the Delta-X Tracker system, which monitors every aspect of the printing process, automatically detecting and flagging or removing defects to maintain uninterrupted production flow.
- Vertical Resolution of 600 DPI: The vertical resolution of 600 dots per inch (DPI) ensures exceptionally detailed and sharp image quality. This high resolution is ideal for producing intricate graphics and precise text, critical for applications requiring high-quality print outputs such as detailed labels and flexible packaging.
- Horizontal Resolution of 300, 600, 900, and 1200 DPI: The WP-360 offers variable horizontal resolutions ranging from 300 to 1200 DPI. This flexibility allows the system to adapt to various print quality requirements, providing versatility in print detail and speed optimization. Higher resolutions are used for premium-quality prints, while lower settings can be selected to increase printing speeds without significantly compromising quality.
- Head Width of 365 mm: The print head width of 365 mm (approximately 14.37 inches) supports a broad print area, enabling the WP-360 to handle larger formats and wider web widths. This wide print head is particularly beneficial for full-web printing applications, allowing simultaneous multiple-lane printing, which maximizes productivity and material usage.
- Maximum Speed of 500 ft/min at 600 DPI: The WP-360 is capable of printing at speeds up to 500 feet per minute while maintaining a resolution of 600 DPI. This high-speed capability ensures rapid production cycles, making it suitable for high-volume industrial environments where both speed and print quality are essential.
- Drop Volume of 3.5 pL: With a minimal drop volume of 3.5 picoliters (pL), the WP-360 achieves an excellent balance of print clarity and ink efficiency. The small drop size allows for fine detail and smooth gradations in images while also reducing ink consumption, which is crucial for maintaining lower operational costs in large-scale production.
- Ink Delivery System: The WP-360 offers two ink delivery system options: gravity-fed and recirculating. Gravity-fed systems are straightforward and cost-effective, suitable for simpler applications. In contrast, recirculating systems help maintain ink viscosity and temperature consistency, which is beneficial for longer runs and varying environmental conditions, ensuring consistent print quality throughout the production process.
Process Flow
The WP-360 operates through a meticulously designed process flow that ensures efficiency and precision throughout its operations. This system seamlessly integrates various stages, from initial feeding and alignment to final verification, each tailored to enhance throughput and ensure the highest quality of end products. This comprehensive approach not only speeds up production but also minimizes errors, making it an indispensable solution for industries requiring high precision and reliability.
- SJ365 Wide-Format Smart Jet: Handles large-format UV digital printing across the full web width of 14.3 inches. The system’s advanced print head technology ensures high-resolution output at 600 DPI, suitable for detailed and complex graphics.
- UV Curing System: Integrates directly after the printing module to instantly cure the ink, making it adhere to various substrates and ensuring durability and quality of the print, regardless of material porosity.
- VS1000 Vision Scan Camera: Employs a high-resolution line scan technology to inspect the web width thoroughly. It checks for print quality, alignment, and any defects in real-time, utilizing advanced image processing algorithms.
- Defect detection and management: Identifies any inconsistencies or quality issues within the print. The system tags defects for removal or flags them for review, ensuring that only products meeting quality standards proceed to the next stage.
- Automated labeling and packaging: Post-inspection, products that meet the quality standards are forwarded to the labeling and packaging stages. This part of the workflow involves automated systems that apply necessary labels and prepare the products for shipping.
- Quality assurance reporting: The Delta-X software compiles comprehensive reports on product quality, defect rates, and system performance, providing valuable insights for continuous process improvement.
- Delta-X Tracker: Serves as the central control software for the WP-360 system. It manages data tracking and integrity across the printing process, providing predictive analytics, maintenance alerts, and repeatable product setups. This software ensures that every part of the print process is monitored and optimized for quality and efficiency.
- Integration with Existing Line Equipment: Seamlessly connects with other in-line systems such as roll splicing, foil stamping, and RFID tagging. This integration allows for a unified operation where all processes are controlled via the Delta-X interface, enhancing operational coherence and reducing the need for multiple control points.
Included Technologies
The WP-360 incorporates a range of advanced technologies that collectively boost its performance and versatility. Featuring state-of-the-art sensors for accurate data collection, sophisticated software algorithms for seamless process integration, and robust mechanical components designed for longevity and precision, the WP-360 stands out as a technologically advanced solution. These technologies are pivotal in delivering the system’s promise of high productivity and consistent quality, tailored to meet the dynamic demands of modern manufacturing environments.
SJ Series
DOD Inkjet
Smart Jet uses industry leading head technology to deliver UV Cured 600 DPI DOD Ink onto any surface.
BSC-1000
Barcode and Data Reading
A user-friendly, fully packaged CCD reader, offering easy integration and several configurations to meet a variety of needs.
UVL-7550
LED UV Curing Technology
The UVL-7550 integrates high-power LED UV lamps for superior, high-speed, single-pass drying and curing applications. Offering an eco-friendly solution with significantly reduced power consumption compared to traditional systems.
BA-250
High-Speed Pack-Out
Fulfillment System
Maximize efficiency with the BA-250, a fully automated pack-out fulfillment system designed for wrapping, inline batching, bundling, and labeling, enhancing throughput up to 2,000 bundles per hour.
Revolutionize Pack-Out with Precision Automation
The BA-250 Pack-Out Fulfillment System is Pack-Smart’s state-of-the-art solution for inline batching, wrapping, and aggregate labeling, delivering up to 2,000 finished bundles per hour with precision and reliability.
This advanced system seamlessly integrates key functions, including batching, wrapping, scanning, weighing, and quality assurance. Each bundle, case, and pallet is labeled with pinpoint accuracy, streamlining workflow efficiency and ensuring end-to-end traceability for high-demand production environments.
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Fast Moving Consumer Goods
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Pharmaceutical Products
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Open Loop Cards
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Closed Loop Cards
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Membership & Loyalty
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Serialized Products
Streamlined Production
- Enhances on-time delivery with integrated packaging processes.
- Produces up to 2,000 bundles per hour, accelerating market readiness.
- Fully automated system reduces the need for manual intervention, lowering labor costs.
Quality Assurance
- Incorporates a QA station that rejects and remakes bad products on the fly.
- Ensures 100% product integrity and quality with advanced scanning and weighing technologies.
- Automated labeling system maintains accuracy and consistency across all bundles.
Advanced Integration
- Utilizes camera-based aggregation to ensure precise product grouping.
- Weight verification of each bundle confirms the correct number of products before packaging.
- Delta-X control system offers real-time data traceability and advanced reporting capabilities.
Watch the Pack-Out Fulfillment System in Action
- High-speed vibratory bowl for product alignment
- Redundant buffering systems to maintain continuous operation
- Advanced rotary motion pick and place for precise product placement
- Integrated weighing and scanning for accurate quality control
- Servo-controlled system for flexible and efficient operation
- Capacity: Up to 2000 finished bundles per hour
- Label placement accuracy: ±1 mm
- Rejection rate: Less than 2%
- Power requirements: 230 V AC, 3 phase, max 30 A
Process Flow
The BA-250 exemplifies streamlined operational excellence, featuring a process flow that optimizes speed and precision. From material handling to the final inspection, each stage of the process is meticulously engineered to enhance productivity and ensure the highest quality output.
- VF900 Vibratory Bowl Feeder: Utilizes vibration technology to orient and sort products efficiently, ensuring they are correctly sequenced for packaging.
- Axode Camera System: Scans and verifies each product for correct sequence and range, enabling accurate tracking and initiation of variable print and apply label content.
- Transport Conveyor: Moves the verified products into the batching module, maintaining a consistent flow to optimize the handling process.
- BC20-03 Batching Module: Collects products and organizes them into specified counts or sequences, preparing them for bundling.
- Alma Flow Wrapper: Encases grouped products in a protective wrap, securing them for the labeling process.
- PAP3000 Print and Apply Labeler: Automatically generates and applies labels to each bundle, ensuring each package is accurately labeled with essential tracking information and product details.
- Weigh Check Module: Conducts a detailed weight verification of each packaged bundle to ensure it contains the correct number of products, essential for maintaining quality control.
- Bundle Divert System: Actively diverts bundles that do not meet specified criteria (e.g., incorrect product count or mislabeling) for reprocessing, ensuring only conforming products proceed to final packaging.
- Hardy Check Weight Module: Provides a secondary verification to re-confirm the accuracy of each bundle’s weight, facilitating a final quality check before the products are cleared for dispatch.
- HMI10 Human Machine Interface: Offers a user-friendly interface for system control and monitoring, allowing operators to make real-time adjustments and respond to system alerts efficiently.
- Delta-X Real-Time Data Controller: Governs the entire system, providing advanced data traceability, integrity reporting, mix-up prevention, predictive analytics, and maintenance scheduling. This technology ensures high operational reliability and repeatability in product setups.
Included Technologies
The BA-250 integrates a suite of cutting-edge technologies that elevate its operational capabilities. It incorporates advanced sensors for real-time monitoring, precision actuators for accurate material handling, and sophisticated software for seamless automation.
These technologies work in harmony to ensure the BA-250 delivers exceptional performance, making it a robust solution for industries seeking to leverage technological advancements for improved efficiency and quality.
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.
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.
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.
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.
MD-200
Multi-Stream Finishing
and Packaging System
Elevate your medical kit production with the MD-200, a multi-stream system engineered for high efficiency and precision in assembling and packaging medical-grade antigen test kits.
Unmatched Efficiency in Medical Kit Production
The MD-200 streamlines the final assembly of medical kits through its advanced multi-lane capabilities. Each production lane meticulously adds components, folds carriers, applies DOD serialization, and securely guides kits into wrapping modules, enhancing throughput and precision.
Medical Kits
Pharmaceutical Products
Fast Moving Consumer Goods
Efficiency
- Multiple-stream technology supports simultaneous kit assembly.
- Achieves a production speed of 200 PPM, optimizing throughput.
- Quick changeover capabilities minimize downtime between production runs.
Precision
- Advanced servo-driven system ensures precise component placement.
- DOD serialization for accurate tracking and compliance.
- Real-time data tracking and validation enhance product integrity.
Cost-Effectiveness
- Reduces labor costs with automated multi-lane processing.
- Lowers per-unit production costs through efficient design and operation.
- Minimizes waste with precise material handling and usage.
Watch the Multi-Stream Finishing and Packaging
System in Action
- Multi-Lane Configuration: Simultaneously assembles multiple kits, increasing throughput.
- Integrated DOD Inkjet Printing: Offers high-resolution serialization directly on components, enhancing traceability.
- Automated Quality Control: Utilizes advanced sensors and cameras to ensure each kit meets exact specifications.
- Servo-Driven Precision: Features digital brushless servo motors for precise motion control throughout the assembly process.
- Real-Time Data Monitoring: Incorporates a system for instant data tracking and validation to ensure production accuracy.
- Advanced User Interface: Equipped with a sophisticated HMI (Human Machine Interface), enabling easy control and monitoring of the system.
- Throughput Capacity: Capable of handling up to 200 kits per minute, optimizing production efficiency.
- Quick Changeover: System design allows for rapid adjustments, with changeovers taking just 2–3 minutes.
- Serialization Technology: Utilizes Drop-on-Demand (DOD) inkjet printing at 600 DPI for detailed and durable markings.
- Material Handling: Designed to work with a variety of packaging materials, including sensitive medical components.
- Operational Dimensions: Accommodates multiple lanes with adjustable settings to handle different kit sizes and configurations.
- Compliance and Safety: Meets high standards for medical device production, ensuring compliance with regulatory requirements.
Process Flow
The MD-200 Metal Detector plays a crucial role in the quality assurance process by integrating seamlessly into the production line to detect metallic contaminants. Products pass through the detector, where high-sensitivity sensors scan for any metal fragments. Upon detection, the system signals the rejection mechanism, promptly removing the contaminated product from the line.
- Single-Stream Buffer Transport Module: Manages the flow from upstream assembly to maintain continuous production without bottlenecks.
- RP300 Rotary Pick and Place Feeder: Accurately places components into the system with high precision, preparing them for wrapping and sealing.
- E10 Wrapper with 4-Side Seal: Ensures each medical kit is securely sealed, maintaining product integrity and sterility with precise four-side sealing.
- DF400 Desiccant Feeder with Bulk Unwind Station: Integrates desiccants into the packaging, cut and dispensed synchronously with the packaging speed.
- SJ75 DOD Inkjet System with Controller: Applies high-resolution UDI codes and other critical information directly onto the packaging film.
- DV250 Divert Module: Diverts any non-conforming kits out of the production line, ensuring only products that meet quality standards proceed.
- VSC1000 Vision Scan Camera: Inspects all print work for accuracy, clarity, and placement, ensuring compliance with quality standards.
- HMI10 Human Machine Interface and Allen-Bradley System Motion Control: Provides central control and monitoring of the entire system, allowing adjustments and real-time tracking.
- Delta-X Tracker Real-Time Data Controller: Offers end-to-end data traceability, tracking critical data for compliance and production efficiency.
Included Technologies
The MD-200 leverages Delta-X software for real-time control and end-to-end reporting, ensuring precision in medical kit assembly. Its servo-driven mechanisms enhance placement accuracy and speed, while its seamless integration with high-speed DOD printing meets stringent regulatory demands, significantly boosting throughput with minimal downtime.
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.
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.