DVD Packaging Machine Overview:

The Merlin DVD packaging machine is a high-speed DVD Amaray case collator. The system fully automates the assembly of DVD cases at 45 cases per minute. A title sheet, two discs, three booklets / coupons and one sensormatic tag can be placed in each case before closing cases.  Empty cases are loaded onto a bulk input shelf positioned along the rear length of the machine. Discs are loaded on spindles into two carousels. Each carousel can accomodates five spindles. DVD title sheets are loaded into a hopper that can accomodate as many as 1500 title sheets. Approximately 1500 of each title booklets are loaded into three vertical hoppers located along the lower rear of the machine.

DVD Assembly Automation Steps:

Cases are pulled one by one from the bulk case hopper. An operator replenishes the case hopper with empty cases every few minutes. Title sheets are first inserted underneath the clear outer liner of each case. Cases are subsequently inserted into an indexing conveyor. At each index position along the conveyor the system places discs, coupons, and if required a sensormatic tag. Cases are can be ejected open or closed from the system.

A touchscreen panel is provided to serve as a comprehensive user interface to the system. All functions of the system are enabled or disabled from the touchscreen panel. The touchscreen panel facilitates troubleshooting and provides operating diagnostics.