Automatic picking and packing system
Our automatic counting and packaging systems enable a significant increase in efficiency with maximum counting accuracy when it comes to automatically picking and packing small parts sets (such as assembly kits for furniture, switch cabinets, and other DIY assemblies).
The products are separated and counted according to type using product-specific Vibrationary counting bowl (also known as vibratory spiral feeder or vibratory bowl feeder) with product-specific counting technology and sensors.
A Vibrationary counting bowl is a system for singulation, sorting, and feeding of bulk goods or small parts such as screws, nuts, dowels, etc. The parts are fed into vibrating bowls as loose bulk goods and transported upwards by a spiral track on the inside of the bowl, where they are oriented in the correct position and separated to ensure accurate counting.
Optionally, a manual workstation can be integrated for the adding special parts or package inserts like manuals .
A synchronized chain tray conveyor collects the counted products at each station equipped with a vibrating bowl in a bowl and finally transfers the picked goods to the packaging machine, which securely bundles the products in the desired packaging.
Optionally, a labelling and/or printing machine can be integrated.
- Speed up to 35 ppm possible
- Maximum process reliability thanks to maximum & reproducible counting accuracy
- Optional labeling with label or direct printing
- Individual packs or connected chain packs
- Use of many film materials, such as PP, PE, or heat sealable paper.
- Integrated photocell control for printed film
- Individually adjustable target quantities for each vibration unit
- Intuitive operation and parameterization via touchscreen
- Freely selectable number of vibratory spiral conveyors allows for an almost unlimited number of different items per set
- Tailor-made packaging system designed specifically for your products
- Modular design enables quick changeover of vibration units for high product flexibility
- Extremely short payback periods of just a few months with appropriate utilization
- Low wear, low maintenance costs
- Wide range of bag sizes
- Speed up to 35 ppm possible
- Maximum process reliability thanks to maximum & reproducible counting accuracy
- Optional labeling with label or direct printing
- Individual packs or connected chain packs
- Use of many film materials, such as PP, PE, or heat sealable paper.
- Integrated photocell control for printed film
- Individually adjustable target quantities for each vibration unit
- Intuitive operation and parameterization via touchscreen
- Freely selectable number of vibratory spiral conveyors allows for an almost unlimited number of different items per set
- Tailor-made packaging system designed specifically for your products
- Modular design enables quick changeover of vibration units for high product flexibility
- Extremely short payback periods of just a few months with appropriate utilization
- Low wear, low maintenance costs
- Wide range of bag sizes
Our automatic counting and packaging systems are ideal for the mechanical picking and packaging of:
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Fasteners & connection technology (e.g., screws, nuts, washers, dowels, allen keys)
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DIY and furniture assembly kits (e.g., kits for flat-pack furniture, shelves, switch cabinets)
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Technical accessories (e.g., luster terminals, fuses, batteries)
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Food (optional, with corresponding design): Sausages, cheese balls, candies, portion packs
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Other small items: Tablets, tubes of glue, toys (e.g., Lego bricks), promotional items
The flexibility of the system allows it to be used in a wide variety of industries – from the furniture industry to electrical and sanitary engineering to non-food and food packaging.
When is it worth automating set creation? A sample calculation:
The following example set is provided for illustrative purposes only:
A typical assembly kit for DIY furniture consists of:
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4 wood screws (e.g. 4 × 50 mm, galvanized)
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6 wooden dowels (e.g., 8 × 30 mm, beech)
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1 tube of wood glue (e.g. 20 ml)
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4 metric allen screws (e.g. M4 × 12, ISO 4762, stainless steel A2)
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4 washers (e.g., 4.3 × 9 × 0.8, ISO 7089)
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1 Allen key (e.g., 3 mm, black burnished)
Total: 6 different products / 20 individual items per bag
Automatic process (with counting and packaging system)
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Speed: approx. 20–25 Sets per minute → 1.200–1.500 Sets per hour
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Operating personnel: 1 person, who fills the vibrating bowls and repackages the finished sets in trays or boxes.
- Counting: Automatically performed via vibratory spiral conveyors with counting sensors
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Sealing: Done automatically by vertical form‑, fill- and seal-machine (VFFS)
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Advantage: Consistent performance without breaks, illness, or mistakes
Manual process (manual picking + sealing)
Based on empirical values and time studies, the average performance per employee is as follows:
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Picking time per set: Approximately 20–25 seconds (careful counting, sorting, filling)
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Threading bags into the continuous table top heat sealing device: approx. 2–5 seconds
Realistic: 2–3 sets per minute / 120–180 sets per hour
➡️ Required: at least 7–13 employeesto keep up with the machine’s output of 1,200–1,500 sets/hour
⚖️ Conclusion – Economic advantage of automation
| comparison criterion | manual | automatic |
|---|---|---|
| Output per hour | Approximately 120–180 sets per employee | Approximately 1,200–1,500 sets in total |
| Required staff | 7–13 persons plus repackaging | 1 operator, including partial repackaging |
| Counting accuracy | prone to errors | highly precise |
| Availability | depending on breaks, illness, vacation | constant, predictable |
| Sealing | separate, time-consuming | integrated |
Information: This calculation takes into account no counting mistakes, no sick leave or breaks as well as no ergonomic disadvantages at manual work – all aspects in which the automated solution scores extra points. In addition, premade bags (as often used in manual packaging) compared to tubular bag packaging significantly more expensive, which is increasing the economic efficiency of the automatic system even more..
It should be noted, however, that such an increase in efficiency requires correspondingly large batch sizes.
The products to be packaged are sorted by type as loose bulk goods in individually customized vibration bowls . Here, singulation, orientation, and counting with great accuracy is carried out. Depending on the product, different counting systems are used, such as:
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Light barrier-controlled collection / timing hoppers
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Magazines with pneumatic product release
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vision based optical counting systems (optional)
A clocked chain bowl conveyor takes the items step by step from the respective stations and forms a complete set from them. The set is then transferred to a vertical packaging machine (VFFS) .
Optional:
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Manual working station for adding special parts, package inserts, or assembly instructions cnm be integrated
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Printing and/or labeling
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Integration of collection tables for ergonomic further processing
The entire system is controlled via the packaging machine’s central PLC, while operation and recipe selection are carried out via an intuitive 7″ touch panel.
The following options are available for clear traceability and optimal product labeling:
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Labeling directly on the bag via labeling machine (optionally with integrated printer for printing labels)
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Direct printing on packaging film via integrated thermal transfer or inkjet printers (CIJ or TIJ)
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Printing of order-specific contentsuch as customer logos, product details, or safety instructions
Customer-side integration of existing printing or labeling systems possible:
Upon request, we will gladly examine the possibility of integrating existing printers and labelers into our control system. This not only ensures a familiar operating environment, but also reduces storage costs through uniform consumables management.
Our counting and packaging systems offer:
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Speed up to 35 ppm (depending on products and quantities)
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Maximum counting accuracy and great process reliability
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Unlimited number of feed stations – Scalable depending on product variety thanks to individual system design
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Product-specific adjustable vibratory bowls
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Great Flexibility thanks to its modular design (quick change of conveyor pots possible, allowing the system to be used for different products while maintaining a compact design)
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Individually definable target quantities per product
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Suitable for all heat-sealable film materials (including PE with special sealing tool)
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Fast return on investment for corresponding quantities
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Low wear and tear, low maintenance, low operating costs
The machines are robust, user-friendly, and designed for long-term efficiency—ideal for replacing manual packaging processes.
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