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.
CC-800
Folding Carton
Check & Defect
Detection System
The CC-800 Carton Check is a high-speed folding carton inspection system designed to integrate ahead of existing folder-gluer equipment or operate offline as a standalone inspection module.
It combines 8K vision, controlled lighting, servo-driven feeding, vacuum transport, PDF artwork verification, AI-assisted defect classification, reject handling, operator control, and Delta-X Trust production tracking.
Inspection Control Before Defects Move Downstream
Folding carton defects become more expensive once they move into gluing, packing, release, or customer delivery. Print errors, registration issues, colour deviation, surface contamination, flap orientation problems, glue pattern defects, folding inconsistencies, barcode legibility issues, and job mix-ups can create waste, rework, release delays, and customer exposure.
The CC-800 adds a controlled inspection point before folder-gluer operations. Carton blanks are fed, stabilized, inspected, classified, rejected when required, and recorded before non-conforming product moves deeper into production.
This is not only defect detection. It is defect containment, inspection logic, and production data control in one modular system.
Folding Cartons
Paper & Corrugated Material
Defect Containment
- Inspects every carton blank before it enters downstream folder-gluer operations, helping contain non-conforming product earlier in the process.
- Detects print errors, registration issues, colour deviations, surface anomalies, flap orientation, glue pattern, folding integrity, barcode legibility, and full-surface graphic defects.
- Optional divert handling removes defective cartons from the production flow before defects create additional waste, rework, or release exposure.
Operator Control
- Touch screen HMI, wizard-driven setup, recipe control, and customizable inspection parameters help operators manage inspection without unnecessary complexity.
- AI-assisted defect classification helps distinguish true carton defects from dust, debris, material variation, and pseudo-errors, improving inspection confidence and reducing unnecessary rejects.
- Real-time defect feedback, live tuning, reports, and analytics support faster decisions during setup, production, and quality review.
Production Reliability
- Servo-driven feeding, vacuum transport, electrical height adjustment, and encoder synchronization support controlled carton movement ahead of existing folder-gluer equipment.
- Roll-in / roll-away configuration and offline operation with a short shingle conveyor give production teams flexible inspection options without replacing current gluer assets.
- Delta-X Tracker logs inspection events, defects, rejects, reports, and reconciliation data, creating a traceable production record for future connected production visibility.
Watch the CC-800 in Action
- 8K Vision Inspection: Captures high-detail carton images across the product surface for print, registration, colour, surface, flap, glue, fold, barcode, and full-graphics inspection.
- Controlled Lighting System: Improves image consistency and defect visibility at production speed.
- 100% Carton Blank Inspection: Inspects every carton blank before it enters downstream folder-gluer operations.
- PDF Artwork Verification: Compares live carton output against approved production artwork to identify print, graphic, barcode, registration, and static data deviations.
- AI-Assisted Defect Classification: Helps distinguish true carton defects from dust, debris, material variation, and pseudo-errors.
- Servo-Driven Carton Feeding: Maintains controlled product transfer, count, position, and inspection timing
- Vacuum Conveyor Transport: Stabilizes carton blanks through the inspection zone for consistent image capture and controlled handling.
- Pre-Feed Folder-Gluer Integration: Positions the inspection module ahead of the folder-gluer feed section so cartons can be inspected before folding and gluing.
- Electrical Height Adjustment: Aligns the module with folder-gluer infeed height to support setup and controlled integration.
- Optional Divert Module: Removes defective cartons from production flow before they continue downstream.
- Touch Screen HMI: Provides access to setup, recipe selection, inspection thresholds, live tuning, diagnostics, and reporting.
- Delta-X Tracker Integration: Logs inspection events, defect records, reject activity, reporting data, and production records.
- Primary Application: Folding carton blank inspection.
- System Type: Pre-feed folding carton inspection system.
- Operating Modes: Folder-gluer integrated inspection, standalone offline inspection, and modular roll-in / roll-away operation.
- Vision System: 8K camera system with controlled lighting.
- Inspection Coverage: Print accuracy, registration, colour deviation, surface anomalies, flap orientation, glue pattern, folding integrity, barcode legibility, static and dynamic data fields, and full-surface graphics.
- Artwork Verification: PDF comparison against approved production files.
- Defect Classification: AI-assisted inspection with deep learning capability.
- Motion Architecture: Servo-driven system architecture for controlled product transfer, count, position, and detection timing.
- Material Handling: Carton feeder with vacuum conveyor transport through the inspection zone.
- Folder-Gluer Integration: Bridging module, electrical height adjustment, and rotary encoder synchronization for folder-gluer integration.
- Reject Handling: Optional divert module for non-conforming carton removal.
- Software and Data Layer: Delta-X QCVision and Delta-X Tracker for inspection control, defect logging, event tracking, reporting, reconciliation, and future SiteCentral connectivity.
Process Flow
The CC-800 Carton Check integrates controlled carton feeding, vacuum transport, 8K vision inspection, AI-assisted defect classification, reject handling, and Delta-X production tracking into one pre-feed inspection workflow for folding carton production.
- SF-500 Smart Feeder: Uses high-performance brushless servo motors managed by a motion controller to support precise carton feeding at production speed. The feeder is designed for continuous operation, controlled product transfer, and quick setup through the touch screen HMI.
- VC-500-12 Vacuum Conveyor: Stabilizes carton blanks through the inspection zone with vacuum-controlled transport that can adjust for different substrate thicknesses and widths. This supports consistent image capture, controlled handling, and reliable transfer toward downstream folder-gluer integration.
- Folder-Gluer Bridge Module: Transfers inspected cartons from the CC-800 into existing folder-gluer equipment. Electrical height adjustment and rotary encoder synchronization support controlled alignment, speed matching, and product transfer.
- Roll-In / Roll-Away Configuration: Allows the inspection module to be positioned ahead of the folder-gluer when needed, moved away when not in use, or operated offline with a short shingle conveyor.
- 8K Vision Camera Inspection System: Captures high-detail images of every carton blank to inspect print quality, registration, colour variation, surface anomalies, flap orientation, glue pattern, folding integrity, barcode legibility, and full-surface graphics.
- LED Illumination System: Provides controlled lighting conditions for the inspection cameras, improving contrast, clarity, and defect visibility across different carton surfaces, coatings, colours, and graphic layouts.
- PDF Artwork Verification: Compares live carton images against approved production artwork files to identify print, graphic, barcode, registration, and static data deviations before cartons move downstream.
- AI-Assisted Defect Classification: Uses deep learning capability to help distinguish true carton defects from dust, debris, material variation, and pseudo-errors, improving inspection confidence and reducing unnecessary rejects.
- Delta-X Tracker: Acts as the production data layer for the CC-800, logging inspection events, detected defects, reject activity, images, classifications, and reporting data in real time.
- Reject Handling: When configured with the optional divert module, the system can remove non-conforming cartons from the production flow before they enter downstream folder-gluer operations or return to active production.
- Inspection History: Inspection data, defect images, classifications, and production history can be stored for retrieval, reporting, review, and historical analysis across jobs and production batches.
- Traceability and Reconciliation: Supports inspection reporting, defect tracking, production record creation, and future connectivity with Delta-X SiteCentral for broader plant-level visibility.
- Emerald 2500 Configurable System Motion Controller: Coordinates feeding, vacuum transport, inspection timing, reject handling, and output transfer. It supports synchronized operation between the CC-800 and existing folder-gluer equipment while maintaining controlled throughput.
- Delta-X QCVision: Connects image capture, defect classification, PDF artwork verification, inspection rules, reject logic, operator control, and production reporting into one inspection workflow.
- HMI10 Human Machine Interface: Provides operators with touch screen access to system setup, recipe selection, inspection parameters, defect sensitivity, live tuning, diagnostics, and reporting.
- Future SiteCentral Connectivity: API readiness supports future connection to Delta-X SiteCentral, enabling inspection data to connect with printing, die-cutting, folder-gluer, quality, and plant-level production systems.
Included Technologies
The
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.
VC Series
Vacuum Transport
High torque servo driven vacuum transport conveys products at accurate speeds and controls product placement with 8 selectable vacuum zones.
DL Series
Shingled Delivery Transport
Discover the DL Series Shingled Delivery Transport, designed for efficient and ergonomic conveying of diverse printed materials.
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.
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.