"With Bronway you get great engineering, great partnership and great automation".
Chief Service & Operations Officer, Netflix Inc.
"By far the most challenging project I've ever been associated with, and they've done a very good job of hitting all of our milestones and any performance we were looking for".
Vice President of Operations Engineering, Netflix Inc.
"..on those three Sleevers, we've processed over one hundred and fifty million DVDs".
The Bronway Automation Compact Tote Palletiser (CTP) has been created to address the need for a safe and automatic palletising system for heavy product totes.
The CTP removes the requirement for operators to manually place totes onto filling stations, wait for them to fill before having to lift the full, heavy tote onto a nearby pallet. A 3 axis pick & place servo system (including our proprietary telescopic Z axis) does all the work by picking, orientating, placing, filling and palletising the heavy totes, all within a securely guarded zone.
Initially a custom machine designed for a large American multi-national medical device manufacturer based in Ireland, the CTP is now a rapidly growing product base for Bronway Automation.
Bronway coupled their standard SL2200 Sleeving line with a print and apply system and a complex software platform to provide Netflix with a robust, high performance solution for printing and applying the synopsis for their DVD Titles. Bronway have currently supplied 3 systems, each having run over fifty million cycles without any issues whatsoever.
The Bronway Mailer Loader (ML1000) is a custom built solution, designed specifically for Netflix Inc. Netflix already had automation for inserting sleeved DVD's into their easily recognisable red mailer, but they called on Bronway when they had a requirement for a faster, more productive platform. Bronway has supplied seventy five units to Netflix and they have proven to be one of the corner stones of their automation program.
The Bronway Automated Rental Return Machine ( the "ARRM") was a custom built solution specifically designed for Netflix's DVD rental returns process. Once a prototype was built and the process proven, Bronway supplied one hundred and eighty production machines to Netflix within a 30 week period, a rate of 6 machines per week.
The SL-2200 is capable of handling a wide variety of sleeve types for 120mm (and optionally 80mm & business card) CDs at rates of up to 75 sleeves per minute.
Sleeve types include Card, Paper (with/without flap), Polypropylene (with/without flap), Tyvek and Safety Sleeve.
Bronway's Sleeving line brings together a number of Bronway's CD/DVD packing solutions.
It consists of the SL-2200 Sleever, the OC-2250 Orientation Conveyor, the TM-2250 Tabbing/Labelling Module and a SA-250 Sleeve Accumulator.
The CSL-2100 is capable of handling a wide variety of sleeve types for 120mm & 80mm CD/DVDs at rates of up to 80 sleeves per minute.
Sleeve types include Card, Paper (with/without flap), Polypropylene (with/without flap) and Tyvek Sleeve.
Specialist & larger Sleeves (190mm X 165mm) can also be handled as an option.
Bronway's SoftPak-260 has been designed to address the growing demand for mid to high-end automated DVD SoftBox Packaging solutions in the most cost effective manner possible.
The Bronway SoftPak TSM-160 is a standalone machine that has been designed to automate the insertion of inlay sheets in to Amaray style DVD boxes.
A choice of box feeders is offered to suit individual budgets and capacity requirements.
The original and still the best, most reliable and accurate spindle counters.
The Bronway IHS-2002 IDENT Inspection Handling System is a mechanical handling system designed specifically to support the high speed automated inspection of IDENT/Bar-Codes on CD/DVD's in a manufacturing environment with minimum operator intervention.
The Bronway Mini-IHS IDENT & Artwork (optional) Inspection Handling System is a mechanical handling system designed specifically to support the automated inspection of CD & DVD's in a manufacturing environment with minimum operator intervention.
This product is ideally suited for full verification of discs (Code & Label) in a multi-disc hand-pack environment thus guaranteeing that the correct disc is being inserted in the correct position of a multi-disc package.
Multiple systems can be networked together in a Master/Slave configuration for simple/automatic or remote setup from your factory wide MIS System.
The Bronway IDV-120 Code Reader has been designed to perform 100% IDENT code verification of discs in-line during the printing and packaging process.
The reader can be fully integrated in to any machine in the Bronway range or installed as an OEM module on to most commercially available printing and packaging machines.
Since most of the discs produced today are identified using barcode technology the reader is optimised for barcode verification, however, an OCR module is available to maintain compatibility with back catalogue.
The Bronway SW-2700 Spindle Shrink Wrap Material Applicator has been designed to apply shrink material to CDs on a spindle being prepared for bulk packing.
The system operates by wrapping shrink material to form a sleeve with a tear strip around the CDs on the spindle prior to shrinking. The sleeve is closed by an impulse-heating element, which forms a clean straight seal on the shrink material. The spindles are fed into and out of the SW-2700 by an integrated conveyor and can be interfaced directly to the ST-2700 Spindle Shrink Tunnel. The SW-2700 is designed to replace manual application of pre-formed sleeves to spindles prior to shrinking thus significantly reducing cost in pre-formed sleeve material and labour.
The Bronway ST-2700 is a bulk heat-shrinking tunnel designed specifically for the CD industry.
The concept is simple -- a neat and economical oven, custom-built for CD spindles, using no more than 5KW of power. The spindles revolve automatically as they pass through the oven giving high speed, low cost and effective results.
The ST-2700, constructed from stainless steel, with its small footprint and efficient power use, is designed to replace both the larger conventional shrink tunnels of the generic type and indeed the laborious heat-gun process still in use.
The Bulk Packing Cell has been designed to reduce labour costs, shrink material costs and electricity costs by having a thermally efficient shrink tunnel.
It is designed in a horseshoe configuration so that the dual role of load and unloading of goods can be completed from the front of the system. The SF-2700 is designed to compliment the SW-2700 Shrink-Wrap Material Applicator and ST2700 Shrink Tunnel and form part of a complete Bulk Packing Solution.
A Bronway IHS-2002 Automated Inspection Module loads the CD/DVD's on to the cakeboxes before sending them to bulk processing. The SF-2700 is designed to compliment the SW-2700 Shrink-Wrap Material Applicator and ST2700 Shrink Tunnel and form part of a complete Bulk Packing Solution.
The Bronway SC-850 CD/DVD Sleeve Collator is a unit designed to automate and simplify the production of CD/DVD sets.
This machine accurately and efficiently collates CD/DVD sleeves into sets and sub-sets of up to 8 per set.
The Bronway SC-1650 CD/DVD Sleeve Collator is a unit designed to automate and simplify the production of CD/DVD sets.
This machine accurately and efficiently collates CD/DVD sleeves into sets and sub-sets of up to 16 per set.
The Bronway 32 Channel CD/DVD Sleeve Collator is a unit designed to automate and simplify the production of CD/DVD sets. This machine accurately and efficiently collates CD/DVD sleeves into sets and sub-sets of up to 32 per set.
A feature of the SC-850 and the SC-1650 is the ability to link multiple systems together to generate even larger CD/DVD sets. For example : two SC-1650 linked together can collate up to 32 CD/DVD sets when operated in linked mode, the systems can also be operated independently with all the features of a standard system.
The Bronway UC-3000 Universal Collator has been designed to facilitate high-speed, low-cost automatic assembly of all the various component parts found in a software package.
Any typical components - from large manuals, through jewel cases and leaflets, to individual license agreements and registration cards - are all easily handled by the UC-3000. This highly innovative machine substantially reduces labour costs, improves product integrity, and will transform your fulfilment process.
The TM-2250 is Bronway's latest In-Line Tabbing (wrap-around/Spine) & labelling module.
The TM-2250 is capable of handling label widths of up to 160mm.
The TM-2250 utilises a pair of spring loaded acetyl rollers to secure the label onto the product. This module comes pre-wired for upstream & downstream communication providing a fully integrated labelling line.
Label placement accuracy is ensured as the labelling head is mounted on a 2-axis lead screw. The TM-2250 is capable of edge tabbing or surface labelling a variety of media packages.
The Bronway 200 DVD Box Stacker consists of an inverter-controlled through-conveyer incorporating a double (2) box simultaneous stacking and counting module.