CGM 400

Collation system for middle-sized to large volumes

The CGM 400 is a unique and highly efficient solution for collating individual layer films before the laminating process. It is the ideal solution for all card manufacturers and with its various advantages and features it ensures significant cost savings and material savings.


Collation table


Overlay processing



Short description

More efficiency for your card production

The CGM 400 was developed especially for the production of small and middle-sized volumes. It offers the advantages of a semi-automatic collating system and still remains inexpensive and effective. A CGM 400 can substitute up to four manual collation tables and can therefore, as a rule, offer a return of investment within 12 months or less. The operation of the equipment is uncomplicated; an operator positions core sheets on the feeder table and adjusts them with the help of the provided guide pins. Afterwards the films are automatically welded together and pushed between the overlay films which are supplied from a roll. If overlays with a magnetic stripe are used, these are automatically brought into the right position. The finished set is spot-welded, trimmed and stacked.


Standard core sheets and overlay foils

  • Card foils made from PVC, PC, ABS, PET and others
  • Different thermoplastics

Final products

Welded card sheet sets, ready for lamination

Collation table

In the first segment of the machine one or several core sheets are placed by the operator on the collating table and are aligned to the head limit stop and side limit stop. Subsequently, the core film set is welded together by the welding heads. The go-ahead for the welding process can be by hand or be previously fixed in the machine programming for a certain time. Optional quality checks like the transmitted light screening function to check for internal objects, the UV printing check to read information which may have been added with UV ink, or a QR code reader to check coherence of the upper and lower sheet, all provide for maximum product safety before subsequent treatment and therefore prevent unnecessary material waste. Optional vision systems visually examine printed markings and check whether these correctly lie on top of each other. If Magtape is being processed, optional cameras can check the exact distance between the tape and printed markings, so that also here no faulty positionings can lead to a useless end product. If requested, missing, or mistakenly twice-introduced, core sheets can be recognised by way of a thickness check even before the welding takes place.

  • Overlay film: min 40 µ
  • Maximum set strength 1.2 mm
  • Different formats, also single strip or half format
  • Transmitted light screening function to check on the presence, and the correct position, of embedded objects like aerials or chips
  • UV printing check for information applied with UV ink
  • QR code reading to check for correct sheet arrangement
  • Vision systems for checking printed markings
  • Distance measurement with cameras between tape and printed markings when using Magtape
  • Thickness check for the recognition of missing or twice-supplied sheets
  • By hand or timer-triggered welding process
  • Various adjustment facilities before onward transport

Overlay feeding and processing

After the pre-welded core sheets have been positioned by the operator, they are carried between the overlay films (with or without magnetic stripe). Besides, the film material is drawn off from two unwinder rollers from above and below and is evenly supplied. Because of the exact adjustment and placing, only a minimum of material is wasted. The collated sheets are welded and afterwards cut automatically before they are transported onto the storage table.

  • Endless overlay of upper and lower finisher
  • Reliable welding of the collated sheets
  • Automatic cutting of the sheet sets
  • Integrated waste bin


The already welded sheets fall, after their trimming, onto an inclined display table. There the sheet sets which are now ready for laminating are collected. By means of a mirror, the operator has a good view of the processed products and can empty the table at the right time. Optionally, they can be collected in an automatic stacker which collects the ready sheets automatically on a trolley. As soon as this is full, the operator receives an announcement from the system and can empty it. The finished sets are clearly much less exposed to external influences and so remain almost completely free from damages. Furthermore the automatic stacker offers the advantage that the operator must not empty the collector constantly by hand and thus the system achieves a higher throughput.

  • Automatic collection of the ready welded and trimmed sheet sets
  • Optionally: electric stacker for the automatic emptying of the collecting table for highest possible throughput

Special features

  • Short set-up times
  • Quick ROI
  • Few movable parts
  • Integrated switch terminal and control panel
  • Practical additional features for even more efficient work
  • Comprehensive quality check for the avoidance of faulty productions and material scrap

Technical specifications

ThroughputUp to 400 Sets per hour (depending on sheet format and operator skill)
Operators needed1
Precision+/- 0,15 mm
Footprintca. 1,8 x 3,6 x 1,8 m

“The CGM 400 is a reliable system that can bring human resource cost and material cost down while staying operator-friendly and precise.”


Do you have any questions? We are happy to talk to you at any time. Write us a message or just call us. We look forward to your inquiry!

Otto Künnecke GmbH
Bülte 1
37603 Holzminden


Fon +49-5531-9300-888