Vacuumatic Vicount 4D Single-Head Paper Counting Machine

Overview

The Vacuumatic Vicount 4D is a high-precision, single-head paper counting system engineered for demanding environments in commercial printing, security printing, tax stamp manufacturing, and packaging operations. It employs opto-mechanical disc-based counting technology—rooted in proven photoelectric interruption principles—to deliver repeatable, non-contact sheet verification at industrial speeds. Unlike traditional mechanical counters reliant on friction or vacuum suction alone, the Vicount 4D integrates configurable optical discs (5-port or 10-port) with intelligent firmware that auto-detects installed hardware and dynamically adjusts operational parameters—including maximum throughput, label insertion capability, and batch logic—ensuring compliance with both process efficiency and material integrity requirements. Designed for GLP-aligned production workflows, the system supports audit-ready data export, password-protected configuration, and time-stamped counting logs—critical for traceability in regulated print environments.

Key Features

• Intelligent dual-disc architecture: Supports interchangeable 5-port (label-insertion enabled) and 10-port (ultra-high-speed only) optical counting discs—automatically recognized by embedded firmware
• Three operational modes: Standard counting (up to 2,500 spm), high-speed counting (up to 10,000 spm), and rapid 100-sheet pack counting (completed in ≤20 seconds per pack)
• 10.1-inch full-color capacitive touchscreen interface with icon-driven navigation—no prior operator training required
• Onboard industrial PC running proprietary counting software compliant with standard CSV/Excel export formats and user-level access control (admin/operator passwords)
• Modular table options: SBT (non-air-float), SFS/MFS/LFS/Industrial air-float variants (760 × 760 mm to 1360 × 760 mm), supporting integration with MIS systems via RS232, USB 2.0 ×3, and RJ45 Ethernet
• Integrated sound/visual alarm system and optional thermal label printer kit for real-time batch tagging

Sample Compatibility & Compliance

The Vicount 4D accommodates a broad spectrum of sheet-based substrates across regulated and non-regulated applications. It reliably counts paper stocks from 25–240 gsm (needle/paddle mode) and 60–210 gsm (disc-based modes), including banknote substrates, security foils, coated labels, and laminated coupons. Minimum sheet dimensions are 60 × 120 mm (standard) and 90 × 45 mm (100-sheet adapter mode). All configurations comply with CE Machinery Directive 2006/42/EC and electromagnetic compatibility standards EN 61000-6-2 / EN 61000-6-4. Optional air-float tables meet ISO 1219-1 hydraulic circuit safety guidelines. Data management features support alignment with FDA 21 CFR Part 11 (when deployed with validated electronic signatures) and ISO/IEC 17025 documentation practices for accredited labs.

Software & Data Management

The embedded counting engine runs on a real-time Linux-based OS with deterministic I/O response. Configuration, batch programming, and diagnostics are managed entirely through the touchscreen GUI—no external PC required. All counting sessions generate timestamped log files containing batch ID, count value, disc type, cycle duration, and operator ID (if authenticated). Export formats include UTF-8 CSV and tab-delimited text, compatible with ERP, MIS, and SAP interfaces. Audit trail functionality records all parameter changes, user logins, and firmware updates—retained for ≥90 days onboard or indefinitely when synced to network storage. Optional MIS data download module enables scheduled FTP/SFTP push to central servers.

Applications

• Commercial printing: High-volume invoice, statement, and direct-mail counting with integrated label insertion for mail-sorting compliance
• Security printing: Precise counting of passport pages, banknotes, and tax stamps where over/under-count penalties trigger regulatory action
• Packaging preforms: Verification of die-cut cardboard blanks, blister card stacks, and pharmaceutical leaflet inserts prior to cartoning
• Label & coupon production: Batch validation of variable-data printed coupons with automated rejection logging for non-conforming stacks
• Paper converting: In-line quality gate for reel-to-sheet conversion lines—ensuring correct stack height before bundling or palletizing

FAQ

Does the Vicount 4D support automatic label insertion during counting?
Yes—but only when the 5-port optical disc is installed. The 10-port disc disables label insertion to prioritize speed; firmware enforces this restriction automatically.
Can the machine count non-paper materials such as thin plastic films or foil-laminated sheets?
It can count rigid or semi-rigid substrates within specified grammage and dimensional limits (e.g., PET film up to 210 gsm equivalent stiffness); flexible films require prior validation using the optional coupon attachment kit.
Is remote diagnostics or firmware update capability available?
Yes—via Ethernet connection using Vacuumatic’s secure remote maintenance portal (requires customer-signed service agreement and firewall whitelisting).
What is the maximum stack height supported in 100-sheet pack mode?
Up to 160 mm (approximately 1,000 notes at typical security paper thickness), with automatic height calibration triggered by the 100-sheet adapter fixture.
Are calibration certificates and IQ/OQ documentation available?
Factory-issued calibration reports (traceable to UKAS-accredited standards) and optional GMP-compliant Installation Qualification (IQ) and Operational Qualification (OQ) packages are available upon order.