Vacuumatic Vicount 3 D Counting Machine
| Brand | Vacuumatic |
|---|---|
| Origin | United Kingdom |
| Model | Vicount 3 D |
| Counting Principle | Rotary Disc |
| Counting Speed | 5,000 sheets per minute (spm) |
| Counting Speed with Flag Insertion | 3,000 spm |
| Cycle Counting Time | 4–5 × 500 sheets / 60 seconds |
| Paper Grammage Range | 60–210 gsm (with 3 interchangeable discs) |
| Minimum Sheet Size | 60 mm × 110 mm (smaller formats available with optional accessories) |
| Maximum Stack Height | 150 mm |
| Batch Count Range | 5–9,999 sheets |
| Cumulative Total Capacity | 999,999 sheets |
| Noise Level | ≤78 dB(A) |
| Base Dimensions (Standard) | 600 mm × 400 mm |
| Base Options | Medium (760 × 760 mm, Airfloat), Large (1060 × 760 mm, Airfloat), Industrial (2040 × 800 mm, Airfoat) |
| Net Weight | Approx. 200–230 kg (varies by base configuration) |
| Power Supply | 230 V / 50 Hz or 115 V / 60 Hz |
Overview
The Vacuumatic Vicount 3 D is a high-precision, industrial-grade sheet counting machine engineered for deterministic, non-contact counting of cut paper, board, security documents, and printed financial instruments. Leveraging Vacuumatic’s proprietary rotary disc counting principle—first patented in 1951 and refined over seven decades—the Vicount 3 D delivers metrological reliability in demanding production environments. Unlike optical or capacitive counters susceptible to static, dust, or surface finish variability, the Vicount 3 D employs mechanically synchronized vacuum-assisted separation and positive mechanical indexing via precision-machined rotating discs. Each rotation lifts, separates, and transports one sheet at a time through a calibrated feed path, eliminating double-feeds and skips even at peak throughput. Designed specifically for packaging, commercial printing, banknote production, and corrugated board manufacturing, the system operates independently of ink density, substrate opacity, or surface coating—making it uniquely suited for high-value, low-tolerance applications where auditability and traceability are mandated under ISO 9001, ISO 15489, and GMP-aligned documentation workflows.
Key Features
- Rotary disc architecture with three user-swappable, hardened steel counting discs optimized for 60–210 gsm substrates—including coated art papers, security laminates, and synthetic banknote substrates.
- Full-color 10.1-inch capacitive touchscreen interface with icon-driven navigation; no prior operator training required for parameter setup, batch programming, or diagnostics.
- Embedded industrial PC running real-time Linux OS with dual Ethernet ports (1× for factory network integration, 1× for isolated data export); firmware compliant with IEC 62443-4-2 security requirements.
- Configurable counting modes: single-batch, multi-cycle, cumulative total, flag-insertion synchronized counting (for serial-numbered vouchers or check inserts), and auto-reset on completion.
- Integrated password-protected access levels (Operator, Supervisor, Administrator) with full audit trail logging per EN 10204 Type 3.1 certification requirements.
- Modular base platform options—from compact tabletop (600 × 400 mm) to heavy-duty industrial Airfoat bases (2040 × 800 mm)—enabling seamless integration into inline finishing lines or standalone QC stations.
Sample Compatibility & Compliance
The Vicount 3 D accommodates a broad spectrum of rigid and semi-rigid sheet materials used across regulated packaging and security printing sectors. Verified compatibility includes offset-printed banknotes (ISO 22320-compliant substrates), thermal-transfer-laminated ID cards, pharmaceutical blister foil stacks, and corrugated linerboard blanks. All mechanical interfaces comply with CE Machinery Directive 2006/42/EC, and electrical design conforms to EN 61000-6-2 (immunity) and EN 61000-6-4 (emission). Optional FDA 21 CFR Part 11–compliant software modules support electronic signatures, change control logs, and secure data archiving for pharmaceutical packaging validation (e.g., USP , Annex 11). Calibration certificates traceable to UKAS-accredited standards are available upon request.
Software & Data Management
The embedded counting software supports CSV, XML, and SPC-compatible .txt exports via USB 3.0 or network share. All count records include timestamp, operator ID, batch ID, stack height measurement (via integrated ultrasonic sensor), and environmental metadata (ambient temperature/humidity if external sensors are connected). Data integrity is enforced via SHA-256 hashing of each session log, with optional AES-256 encryption for exported files. Remote monitoring and firmware updates are supported via HTTPS-based secure OTA protocol. The system natively integrates with common MES platforms (Siemens Opcenter, Rockwell FactoryTalk) through OPC UA 1.04 interface—enabling real-time OEE tracking and automated job dispatching.
Applications
- Commercial print shops verifying run accuracy for high-value short-run brochures, direct mail inserts, and variable-data marketing collateral.
- Security printers performing final reconciliation of banknote, passport, or tax stamp batches prior to vault handover.
- Paper mills conducting QC audits on reel-to-sheet conversion output, especially for premium coated grades destined for luxury packaging.
- Pharmaceutical contract manufacturers counting foil-laminated blister cards pre-packaging, meeting EU GDP Annex 9 and PIC/S PE 009-14 requirements.
- Corrugated converters validating cut-size sheet counts before die-cutting or folder-gluer feeding—reducing downstream misfeeds and waste.
FAQ
What counting principle does the Vicount 3 D use, and why is it preferred over optical methods?
It uses a vacuum-assisted rotary disc mechanism that physically separates and indexes individual sheets. This eliminates dependency on optical contrast, ink coverage, or substrate translucency—critical for security documents and metallized packaging films.
Can the Vicount 3 D integrate with existing ERP or MES systems?
Yes—via standard OPC UA 1.04, Modbus TCP, or RESTful API endpoints. Pre-certified drivers are available for SAP ME, PTC ThingWorx, and Siemens Mendix.
Is calibration required, and how often must it be performed?
Initial calibration is performed at the factory against NPL-traceable reference stacks. Field recalibration is recommended annually or after 10,000 operating hours, using Vacuumatic’s certified calibration kit (part no. VK-CAL-3D-KIT).
Does the system support multi-language UI and documentation?
The touchscreen interface supports English, German, French, Spanish, Chinese (Simplified), and Japanese. All technical manuals, CE declarations, and validation protocols are provided in English with optional localized translations.
What safety certifications apply to the Vicount 3 D in North America?
UL 61010-1 (3rd Edition) and CSA C22.2 No. 61010-1 certification are included as standard. UL listing documentation is supplied with shipment for FDA-regulated facilities.
