Every Product in the Right Place. Every Time.
IntelliPak is a smart conveyor system that creates precise gaps for inspection and batches verified product into exact groups — feeding thermoformers, case packers, flow wrappers, and hand-pack stations at speed.
Your Packaging Equipment Is Only as Good as What Feeds It
Thermoformers, case packers, and flow wrappers are precision machines — but they can't fix what arrives wrong. When product shows up at random intervals with inconsistent spacing, you get misfeeds, incomplete batches, line stops, and throughput you can never fully recover.
Most plants compensate with manual labor or oversized buffers. IntelliPak solves it at the source.
Precision Gapping. Intelligent Batching. Seamless Integration.
IntelliPak uses independently controlled belt zones with photo-eye sensors to read each product's actual position — not assumed timing — and dynamically adjusts belt speed per product. The result is exact spacing for QC and exact grouping for packaging.
Gapping for Inspection
Creates consistent, repeatable gaps between products so your VeriPak vision system (or any QC device) gets a clean look at every single item. Typically runs 2 belts to establish the gap window.
Batching for Packaging
Groups verified product into exact counts — 3s, 4s, 6s, 12s, whatever your packaging format requires. Batch sizes are adjustable on the fly from the HMI. Can run up to 7 belt zones for complex batching patterns.
Timing & Metering
Synchronizes product delivery to your downstream machine’s cycle — matching the thermoformer’s index, the case packer’s cadence, or the flow wrapper’s pitch. Product arrives when the machine is ready for it.
Merge & Divert
Multi-lane to single-lane merging, or single-lane to multi-lane diversion. Mag-Drive precision ensures consistent product spacing through every transition — no contact pressure, no product damage.
In Action
One System. Any Format. Change It on the Fly.
Select a batch configuration and adjust line speed to see the system respond in real time.
Batch sizes and line speeds are configured from the Allen-Bradley Optix HMI — switch formats between runs or mid-shift without stopping the line.
Mag-Drive Precision — No Gears, No Drift, No Limits
IntelliPak is powered by magnetic direct-drive hub motors — a permanent-magnet synchronous design built directly into each conveyor roller. There's no mechanical coupling between the motor and the belt — the magnetic field drives the roller directly.
This matters for product handling because:
Magnetic coupling maintains exact position without the mechanical slop that degrades in gearbox-driven conveyors over time. Your gaps stay precise on day 1,000 just like day 1.
Open-loop synchronous operation eliminates the most common failure point on conventional servo-driven infeed systems. No cables to break, no position loss, no unplanned stops.
No lubricant exists in the system. Period. For food, dairy, and pharma environments, this eliminates an entire category of sanitation risk.
The motor sits inside the roller, reducing the conveyor footprint and simplifying maintenance. No external drivetrain to clean around.
What That Means on the Line
| Metric | Conventional Gearbox | IntelliPak Mag-Drive |
|---|---|---|
| Product spacing accuracy | Degrades over time (backlash) | Constant — permanent magnet sync |
| Batch integrity after reject | Manual re-staging required | Automatic — only verified product batches |
| Speed | 200–350 PPM typical | Up to 500 PPM |
| Changeover (batch size) | Mechanical adjustment | On-the-fly from HMI |
| Encoder cable failures | Common failure mode | No encoder cables |
| Oil contamination risk | Ongoing | Eliminated |
| Energy consumption | Baseline | 55% reduction |
| Sanitation time | Full teardown required | 50% faster — no housings to clean |
| Warranty | Typically 1 year | 3-year AQS warranty |
Designed for Your Line, Not a Catalog
Every IntelliPak system is engineered for the specific product, speed, and environment of your packaging line. Common configurations include:
Smart Infeed Conveyor
Precision product gapping and metering for downstream packaging equipment. 2-belt Mag-Drive configuration creating exact inspection windows at up to 500 PPM.
Batching & Collation System
Multi-belt configuration (up to 7 zones) that groups verified product into exact counts for case packers, thermoformers, or hand-pack stations. Batch sizes adjustable on the fly.
Accumulation System
Buffer zones that absorb upstream/downstream speed differentials without stopping the line. Zero-pressure accumulation prevents product damage.
Complete Line Architecture
Full infeed design from depalletizer to palletizer. IntelliPak feed systems integrated with AQS Custom Conveyors and VeriPak SCADA for end-to-end control and traceability.
Technical Specifications
See What IntelliPak Can Do for Your Line
Start with a project review. We'll evaluate your current infeed, identify where you're losing throughput and batch integrity, and spec an IntelliPak system for your specific application.
Where It Fits in the Line
See how this solution integrates into real production line configurations. Explore AQS products in this line.
Products are inspected and rejected individually, then IntelliPak batches the verified products for case packing — so every batch is complete and correct.
Common Questions
Ready to Eliminate Quality Blind Spots?
Whether you need VeriPak, EvacuPak, leak detection, sanitary robotics, or custom conveyors — let's architect your next system together.
Start a Project Review →