Köster / Koester industrial counting technology

High-performance counting machines, precision counting discs, and optical inspection modules from Köster / Koester provide reliable tallying across paper finishing lines.

Köster / Koester precision counting discs C1, C2, C3, and C6 series

Precision counting discs from Köster / Koester C1, C2, C3, and C6 series provide corner counting for security paper and banknotes. The disc geometry generates vacuum suction across paper weights from 30 to 200 GSM without edge deformation or fiber surface marking.

Substrate weight handling covers paper stocks from 30 up to 200 GSM reliably
Disc outer diameter of 112 mm on C1 variant fits small formats down to 9x32 mm
Calibrated vacuum slit geometry prevents double sheet draws and counting errors
Gentle edge profile separates high-gloss and intaglio printed substrate sheets

Köster / Koester side edge counting discs S6, S7, S8, S10, and S11 series

Side edge counting discs from Köster / Koester S6, S7, S8, S10, and S11 series implement proprietary side sheet separation. The assemblies operate with edge offsets from minus 4 to plus 4 mm, ensuring accurate counting of heavy boards and polymer sheets up to 900 μm.

Side edge counting eliminates physical limitations of traditional corner suction
Variant S11 processes heavy cardboard and thick multi-layer substrates above 500 GSM
Outer diameter of 158 mm ensures steady sheet edge tracking at elevated velocities
Offset tolerance spanning minus 4 to plus 4 mm absorbs stack alignment deviations

Köster / Koester HPC B03 and HPC B04 tabletop counting machines

Tabletop high-performance counting machines from Köster / Koester HPC B03 and HPC B04 series deliver precision batch counting for banknotes, tax stamps, and labels. The single-head units achieve counting speeds up to 200 sheets per second with quiet drive mechanics.

Processing speed reaches 200 sheets per second without edge friction marking
Compact desktop housing suits printing quality control labs and finishing lines
Intuitive digital control screen displays live tally numbers and target batch sizes
Integrated quiet vacuum pump unit simplifies routine factory floor operations

Köster / Koester HPC B12, B15, B18, B22, and B26 industrial machines

Industrial counting systems from Köster / Koester HPC B12, B15, B18, B22, and B26 series provide non-stop tallying across high-volume finishing departments. Available in single, double, and quad-head layouts, the machines incorporate automated sheet curl compensation.

Multi-head Double-Head and Quad-Head layouts multiply output throughput easily
Pneumatic weight compensation system prevents downward pressure on bottom sheets
Automated curl compensation stabilizes sheet tracking across wavy ream edges
Rigid welded chassis dampens mechanical vibration during continuous work shifts

Köster / Koester B09, B20, and B21 built-in counting mechanisms

Integrated counting mechanisms from Köster / Koester B09, B20, and B21 series are built for direct installation into packaging machines, folders, and palletizers. Featuring servo drives, the modules separate precise paper layer counts during automated stacking routines.

Module B09 with integrated servo drive optimizes robotic destacking operations
Model B20 supports horizontal mounting using external drive systems from builders
Unit B21 provides pinpoint count separation of partial sheet batches on conveyors
Direct pulse signal integration into factory PLC units avoids separate controllers

Köster / Koester HELIX CC optical code capturing system

Optical code verification systems from Köster / Koester HELIX CC series inspect serial numbers and identifiers directly inside intact paper reams. The unit reads sheet codes during active counting without physical sheet separation, accelerating security print inspection.

Serial code capturing within full reams without prior mechanical separation
Complete serial number traceability for banknotes, securities, and revenue stamps
High-speed optical imaging sensor synchronized with counting disc rotation speed
Instant flagging of reams exhibiting broken numerical sequence or print defects

Engineering criteria and selection of C1 to C6 precision counting discs

Precision counting discs from Köster / Koester C1, C2, C3, and C6 series are engineered for corner counting of printed paper products, securities, and banknotes.

The operating principle uses vacuum suction to draw the corner of each sheet against a rotating disc contour, separating it gently without creasing or fiber distress. For delicate stocks and small formats such as tax stamps down to 9x32 mm, the C1 disc with an 112 mm outer diameter is ideal.

The C2 disc with 129.6 mm outer geometry represents an industry standard for 30 to 150 GSM stocks. Disc C6 handles stiffer materials up to 200 GSM. Fine adjustment of disc immersion depth and vacuum pressure yields reproducible tallying.

Side edge counting technology for dense reams using S6 to S11 discs

The proprietary side edge counting concept developed by Köster / Koester engineers for S6, S7, S8, S10, and S11 series eliminates the constraints of corner separation. Operating with an outer disc diameter of 158 mm, the unit grips the sheet edge along the side of the stack.

This layout is vital when counting bound brochures, folded leaflets, and rigid cardboard cartons. The disc intake gap tolerates edge misalignment spanning minus 4 to plus 4 mm without missing counts. The heavy-duty S11 variant processes thick substrates up to 500 GSM and 900 μm thickness.

Periodic vacuum cleaning of paper dust preserves suction dynamics.

Operational parameters of HPC high-performance counting machinery

High-performance counting machines from the Köster / Koester HPC range deliver tallying rates up to 200 sheets per second, handling 1,000 sheets in under six seconds.

Operating at such velocity allows under 0.005 seconds to pull, separate, and electronically register each sheet, placing demanding requirements on spindle dynamic balancing and high-speed controller logic.

To prevent compaction of bottom layers, the machines employ pneumatic weight compensation, relieving downward pressure over the separation zone. Operators configure batch quantities via the touchscreen interface, while an automated tape inserter marks sub-batches on the fly.

Pneumatic sheet curl compensation across irregular paper reams

Following printing or prolonged warehouse storage, paper stacks frequently exhibit edge curling and wavy distortion. Köster / Koester equipped HPC B12 through B26 industrial machines with automated curl compensation to counteract upward and downward edge deviations.

Optical tracking sensors monitor the edge profile in real time, prompting micro-actuators to adjust the counting head inclination dynamically. This mechanism avoids skipped sheets when paper edges lift away from the vacuum groove.

Air cylinder suspensions absorb mechanical vibration, ensuring repeatable count accuracy.

Integrating B09 and B20 counting modules into automated packaging lines

Built-in counting mechanisms from Köster / Koester B09, B20, and B21 series are designed for direct installation into packaging machines, folders, and robotic destackers. Compact housing dimensions facilitate mounting within tight mechanical envelopes above conveyor feeds.

The B09 assembly includes an integrated servo motor to meter out exact sheet counts before forwarding layers into shrink-wrapping machines. The B20 configuration accepts external machine drive inputs provided by system builders.

Counting pulse outputs interface directly with plant programmable logic controllers without delay.

Complete serial number traceability using the HELIX CC inspection system

The optical inspection unit Köster / Koester HELIX CC delivers total verification for security print batches during active tallying.

A high-speed digital camera captures two-dimensional matrix codes, barcodes, and alphanumeric serial numbers on banknotes and revenue stamps directly inside intact paper reams without manual sheet separation.

An onboard image processor cross-checks recorded numbers against production databases, immediately identifying skipped sequences, misprints, or duplicate entries. Integrating HELIX CC onto HPC machines eliminates secondary inspection benches, reducing handling overhead.

Köster / Koester and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of Köster / Koester and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.