Advanced Manufacturing
At MOD-PAC, advanced manufacturing is about more than just the machinery that allows us to deliver quality, reliability, and speed on every order. It’s also a mentality of proactive innovation; we plan years ahead, track in-development technology, and ensure we’re ready to bring the latest advancements to our customers. That forward thinking, supported by over $50 million in technology upgrades in recent years, keeps us at the forefront of printing and packaging.
Our production floor features high-performance printing presses, automated folder-gluers with in-line inspection, and precision sheeters that keep every run consistent. This commitment to innovation means faster turnaround, dependable quality, and the capacity to scale with your needs.
Featured Technology
Heidelberg Speedmaster XL 106
Built on next-generation sheetfed technology, this press maximizes automation, speed, and color accuracy across every run. AI-driven systems monitor and adjust settings throughout production, improving efficiency and quality while reducing operator intervention. Integrated logistics automatically handle pallets and feeding, allowing our team to focus on quality control and job preparation.
Machine Highlights
- 21,000 sheets per hour for maximum throughput and efficiency
- Automated pallet handling and logistics for minimal operator intervention
- Faster make-readies and quick changeovers, within minutes instead of hours
- Improved ink and dampening systems for consistent, high-quality color
Palletizing Robot
Designed to automate the palletizing process at the end of MOD-PAC’s high-speed production lines, OSCAR keeps finished goods moving efficiently and safely. As cases travel down the conveyor, OSCAR lifts each completed layer from below and stacks it precisely on a pallet, following custom patterns programmed by our engineering team. Once a pallet is full, it’s automatically transferred for wrapping and shipment.
Machine Highlights
- Palletizes up to 60 pallets per hour, equal to about 2.5 truckloads of product
- Eliminates manual lifting and reduces ergonomic strain on operators
- Maintains precision and consistency at the speed of MOD-PAC’s production lines
- Fully programmable pallet patterns customized for each order
- Reduces potential for mixed copy
Autonomous Mobile Robots
Operating throughout the facility, our AMRs automate material transport between production and shipping. Once OSCAR completes and wraps a pallet, an AMR is automatically dispatched to retrieve it and deliver it to shipping. Guided by intelligent mapping, each robot navigates independently, avoiding obstacles, optimizing routes, and running continuously to keep materials flowing 24/7.
Machine Highlights
- Fully autonomous operation reduces forklift and manual transport needs
- Improves safety, efficiency, and material flow across departments
- Integrates with production and warehouse systems for seamless operation
- Supports MOD-PAC’s continuous automation and advanced manufacturing goals
Sheeter
MOD-PAC operates two high-speed sheeters that convert massive paper rolls into perfectly cut, print-ready sheets. Each roll is unwound, cut, and stacked automatically to match each job’s specifications. Operating at speeds up to 1,300 feet per minute, the sheeter can produce as many as 50,000 sheets per hour. Having two sheeters increases reliability and ensures production stays on schedule, while automatic splicing and precision cutting minimize waste and keep every sheet feeding seamlessly into the pressroom.
Machine Highlights
- Produces up to 50,000 sheets per hour at a speed of 1,300 feet per minute
- Splices automatically into the next roll for uninterrupted production
- Cuts sheets to exact sizes to improve efficiency and enhance sustainability by limiting waste
- Holds roll width of 73 inches to maximize efficiency
Gluer
Once printed and die-cut, cartons are moved through the gluer to be folded, glued, and finished with precision. Built-in quality inspection systems scan barcodes to prevent mixed copy and use glue sensors to verify proper adhesive application. Any defective cartons are automatically removed, ensuring that only perfect cartons are shipped and packaged.
Machine Highlights
- Folds and glues cartons at high speeds for maximum efficiency
- Scans barcodes to ensure accuracy and prevent errors
- Verifies adhesive placement with glue sensors for perfect application
- Ejects defective cartons automatically to reduce waste and rework
Automatic Packer
The CARTONPACK 4 is a high-performance packer that automates the final carton production step by quickly loading folded and glued cartons into shipping containers. Every setting is motor-driven for repeatable, consistent operation across recurring jobs, helping the system keep pace with MOD-PAC’s folder-gluer lines. Standardizing this process boosts output, reduces manual effort, and supports efficient, cost-effective production.
Machine Highlights
- Handles up to 200,000 cartons per hour to match high-speed line output
- Standardizes adjustments with fully motorized, MATIC-based controls
- Tracks count with high accuracy to ensure exact quantities
- Pulls samples for quality checks without interrupting production
Explore More
See What’s Possible With MOD-PAC
Advanced manufacturing is just one part of what sets MOD-PAC apart. Explore our full range of capabilities to see how our expertise in converting, printing, and finishing comes together to deliver packaging that meets your expectations for quality and performance.
MOD-PAC is the source for high-quality custom packaging for consumer product manufacturers worldwide and stock packaging for the retail confectionery industry.
Our Offices
1801 Elmwood Avenue
Buffalo, New York 14207
1-800-666-3722