Automated Vision Counting & VFFS Bagging Machine For New Zealand Customer
A New Zealand-based manufacturer recently approached us with a clear automatic packaging demand. Their current warehouse kitting process is entirely manual: parts arrive from their machine shop in bulk bags, operators use weighing scales to count them, and then manually assemble kits into smaller bags. This process is slow, labour-intensive, and increasingly prone to counting errors as order volumes grow.
Customer Requirements
Their product includes aluminium profile short cuts, plastic gap sealers, door and window hardware, and injection moulded fittings. No single part exceeds 600 grams. Any automated solution must eliminate metal-on-metal or metal-on-plastic scratches during feeding, counting, and bagging. Parts must be bagged in batches of 10, 20, 50, 100, 200, and 500 pieces per bag. The current bag sizes vary, with the largest being approximately 305×380 mm, plus common sizes of 230×305 mm, 130×155 mm, and 100×130 mm. The customer is open to minor adjustments to bag dimensions, but the equipment must accommodate this range.
Our Proposed Solution
After analysing the customer’s parts, quantities, bag sizes, and scratch-free requirement, we have proposed a Modular Vision Counting and VFFS Packing System. This solution replaces manual weighing with automated precision while protecting delicate components.
1.Scratch-Free Feeding & Counting Module
To eliminate scratching, we avoid traditional vibratory bowl feeders. Instead, our slow-speed flat belt feeding system with urethane-lined chutes and soft-landing drop zones ensures parts are never rubbed or impacted aggressively. A high-resolution CCD vision counting sensor positioned above the belt captures each part in flight, achieving 99.9% counting accuracy for kits ranging from 10 to 500 pieces. This combination – vision counting system for hardware parts – is ideal for kitting lines.
2. VFFS Bagging Machine with Multi-Size Capability
Our vertical form fill seal bagging machine is configured to handle the customer’s bag size range. The machine supports bag lengths from 50 mm to 350 mm and bag widths up to 230 mm. For the occasional 305×380 mm bag, we recommend a minor adjustment to 230×380 mm, or a wider film carriage (available as an option). The automatic film forming tube, end seal jaws, and rotary knife cutter are all servo-driven, allowing fast changeovers between different bag sizes and kit quantities.
3. Labelling
An optional thermal transfer auto-labelling module can be integrated downstream of the VFFS outlet. The labeller applies batch number, date code, and scannable barcodes to each bag before it drops onto the output conveyor.
4. Commissioning, Training & Documentation
- On-site commissioning with the customer’s actual parts
- Operator training (daily cleaning, quick changeover)
- Maintenance training (seal jaw replacement, pneumatic servicing)
- Digital SOPs and a maintenance logbook
- Build drawing and mechanical BOM.
This automated vision counting and VFFS bagging machine directly addresses the New Zealand customer’s need for scratch-free handling and precise kitting (10–500 parts per bag). We invite the customer to send part samples for a free validation test, including a video demonstration and counting accuracy report.
Related Case Study: Tubular Packing Machine with CCD Camera Counting – Worldepack-Packing Machine Supplier
