How Do You Package Two Circuit Breaker Models with Full Traceability — at 1.5 Seconds Per Breaker?

A circuit breaker cartoning machine automates the full packaging sequence — from barcode-verified breaker infeed through vision-inspected stacking, literature insertion, label application, and label verification — for two breaker families on one line. This system was built for a returning customer in the electrical components industry who needed to hit a target rate of 255 breakers per hour while adding full barcode and vision traceability to a process that previously had none. The machine uses Keyence SR-1000 barcode scanners at infeed, a Keyence IV vision system for stack count and front-face inspection, a Keyence VS vision system for label quality verification, a servo-driven waterfall stacker, a vacuum pick-and-place carton erecting mechanism, dual barcode-verified media feeders, and a Quadrel tamp-on label applicator with a Zebra OEM print engine. It runs at 1.5 seconds per breaker and changes over between breaker families in under 180 seconds with one operator. SDC drew on proven cartoning building blocks from past projects — carton forming, stacking, and label application methods already proven in the field — then engineered every station specifically for this customer's two-family packaging and traceability requirements. The result is a line that catches every defect before it leaves the plant, with no added operator labor to do it. What's covered in this video: 00:10 — Project overview 00:19 — Breaker infeed & barcode verification 00:33 — Carton forming & erecting 00:56 — Stacking, loading & vision inspection 01:15 — Literature insertion & carton closing 01:29 — Label application & label verification Read the full case study: https://sdcautomation.com/case-study/... #CircuitBreakerPackaging #CartoningMachine #ManufacturingAutomation