COUNT-S Stack Counter by Vacuumatic
| Brand | Vacuumatic |
|---|---|
| Origin | United Kingdom |
| Model | COUNT-S |
| Counting Principle | Non-contact optical stack height measurement |
| Max Stack Height | 450 mm |
| Interface | Color touchscreen display |
| Design | Modular, production-line integrable |
| Intended Use | High-volume sheet-based counting in secure document and pharmaceutical packaging environments |
| Compliance Context | Designed for GLP/GMP-aligned manufacturing workflows requiring audit-ready process traceability |
Overview
The COUNT-S Stack Counter, engineered by Vacuumatic (UK), is a precision optical height-sensing device designed for non-contact, high-speed quantification of stacked planar materials—including PVC smart cards, polycarbonate ID documents, laminated credit cards, folded leaflets, blister-packed inserts, and pharmaceutical说明书 (instruction leaflets). Unlike traditional mechanical or vacuum-based counters, the COUNT-S employs calibrated optical displacement sensing to measure stack thickness with sub-millimeter resolution. It correlates measured height against pre-validated material-specific calibration curves—generated per substrate type, grammage, and compression behavior—to compute count values in real time. This principle eliminates physical contact, preventing surface marking, static discharge, or micro-scratching—critical for ISO/IEC 7810-compliant card surfaces and FDA-regulated pharmaceutical packaging components. The system operates independently of RFID tags, barcodes, or printed identifiers, making it suitable for raw, unmarked stacks prior to final finishing.
Key Features
- Non-contact optical height measurement with automatic compensation for substrate compressibility and environmental drift
- Maximum detectable stack height of 450 mm—supporting standard industrial pallet trays, Euro bins, and custom deep-draw carriers
- Integrated 7-inch color resistive touchscreen interface with intuitive icon-driven workflow navigation
- Modular mechanical architecture: base unit, adjustable sensor mast, optional conveyor interface kit, and programmable I/O module for PLC synchronization
- Factory-calibrated for common substrates: 0.3–1.2 mm PVC/PET/PC card stock, 60–120 g/m² coated paper leaflets, and 200–400 µm laminated foil-polymer composites
- Real-time cycle time logging and count verification timestamping—compatible with electronic batch record (EBR) systems
Sample Compatibility & Compliance
The COUNT-S accommodates rigid and semi-rigid sheet formats ranging from 50 × 50 mm up to 156 × 102 mm (ID-1 standard), with tolerance for ±0.15 mm dimensional variance. It supports both flat-stacked and lightly nested configurations typical in post-lamination, post-printing, and post-cutting stages. Calibration profiles are user-loadable per SKU, enabling rapid changeover between card types (e.g., EMV chip cards vs. magnetic stripe blanks) or leaflet variants (A4 folded vs. DL tri-fold). From a regulatory standpoint, the COUNT-S meets functional requirements for traceability under EU Annex 11 (Computerised Systems), supports 21 CFR Part 11-compliant audit trails when connected to validated MES platforms, and aligns with ISO 9001:2015 clause 8.5.1 (Control of production and service provision) through repeatable, documented counting protocols.
Software & Data Management
Firmware v3.2+ includes embedded data logging with configurable retention (30–365 days), CSV export via USB 2.0 port, and Modbus TCP support for SCADA integration. Each counting event records: timestamp (ISO 8601), operator ID (optional RFID badge scan), stack ID (manual entry or barcode-assisted), measured height (mm), computed count, confidence index (%), and deviation from nominal stack height (±%). Optional Vacuumatic CountLink™ software enables remote diagnostics, calibration profile version control, and statistical process monitoring (SPC) charting—plotting count accuracy trends across shifts, batches, or material lots. All logs retain SHA-256 hash integrity signatures to satisfy GLP audit requirements.
Applications
- Secure document manufacturing: Final QC counting of finished bank cards prior to embossing, personalization, or packaging
- Pharmaceutical secondary packaging: Count verification of patient information leaflets before insertion into cartons or blisters
- High-security ID production: Batch reconciliation of e-passport data pages or biometric visa inserts
- Contract packaging facilities: In-line verification of label sets, instruction sheets, or desiccant pouches per SKU
- Print finishing operations: End-of-line validation for folded brochures, warranty cards, or compliance documentation
FAQ
Does the COUNT-S require periodic recalibration?
Yes—calibration must be performed at startup, after ambient temperature shifts >5°C, and following any substrate change. Vacuumatic recommends daily verification using NIST-traceable reference stacks.
Can it count warped or curled sheets?
It is optimized for flat-to-moderately-cupped stacks. Severely curled or buckled sheets (>3 mm edge lift) reduce measurement fidelity; pre-flattening via roller conditioning is advised.
Is the system compatible with cleanroom environments?
The COUNT-S base unit meets ISO Class 8 (Class 100,000) particulate limits when installed with optional HEPA-filtered air purge; full Class 7 integration requires custom enclosure engineering.
What safety certifications does it hold?
CE marked per Machinery Directive 2006/42/EC and EMC Directive 2014/30/EU; RoHS 2011/65/EU compliant; no laser classification required (Class 1 LED-based optics).
How is firmware updated?
Via signed .ufw package loaded from FAT32-formatted USB drive; updates preserve all calibration profiles and audit log history.
