Application Description

Batch-counting, printing, accumulating, and shrink wrapping promotional cards

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Application Details

A large printing company sought out an automation solution for the fulfillment process of counting and printing database-driven entry codes on millions per week of CR-80 promotional cards for a joint venture between a national consumer retail chain and a household name consumer products company.

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The PrintStar System feeds, counts, database prints, and batches 75 cards per set at a rate of over 60,000 per hour. The XM-21 High-Speed Batch Count Feeder, equipped with the NEW Vacuum Belt Extension and Solvent Based Printer, prints the stream of cards at up to 1,000 feet per minute. The cards are then batched in the NEW Victory Rotary Star-Wheel Dropper for dispensing as a stack into the lugged infeed of the shrink wrapper.

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By integrating the printing and counting of the cards inline with the wrapper, the printing company was able to eliminate an entire process with 3 full time equivalents across 3 shifts, 5 days per week.

The PrintStar System can be configured to run products 2" x 3" up to 12" x 12", and from single sheet thickness to 3/4" thickness. The PrintStar System can be configured to interface with any style packing system, including wrappers, cartoners, banders, strappers, and more.

Superior-PHS can provide any combination of the above modules for your application or a complete turnkey system with wrapper and shrink tunnel to meet your specific application requirements.