Integrating a Card Feeder with a Flow Wrapper

Why integrate a feeder with a flow wrapper

Pairing a card feeder with a flow wrapper turns two separate steps into one continuous operation: cards are singulated, dropped into the film, and sealed in a single pass. This removes manual loading, lifts throughput, and improves pack consistency.

How the hand-off works

The feeder's outfeed conveyor aligns the card with the wrapper's infeed. As the card reaches the film, the wrapper pulls it in and the fin-seal jaws close. A mechanical or vacuum transfer bridge keeps the card centered during the hand-off.

Signal and timing essentials

The feeder and wrapper exchange signals through the PLC: the wrapper requests a card (or the feeder confirms one is ready), and both machines share an encoder or cycle clock so the card arrives exactly when the jaw opens. Photoelectric sensors confirm placement before sealing.

Common integration layouts

• Single feeder → single wrapper for one-card packs
• Two feeders (card + leaflet) → one wrapper for kit packs
• Feeder + pouch dispenser → wrapper for desiccant-included packs
• Multiple wrappers fed from one collation buffer for high volume

Validation before shipment

Before a line ships, CHANFER runs it with the customer's real cards at target speed, checks missing-card and double-feed detection, and tunes timing so reject rate stays near zero. Only then is the line released.

Typical throughput examples

A CR80 card at 500 cards/min feeds a wrapper running ~500 packs/min; a thick booklet handled by a push feeder sets the pace for lower-rate, higher-value kit packs. Sizing the feeder to the wrapper's bottleneck is what keeps OEE high.