Technology

Hybrid Counting Mode

More throughput when the product allows it, and precise control when the final count has to land exactly.

Higher throughput Controlled handover Modular design Origins: ASTRA-1P

What it is

Hybrid Counting Mode is a patented XIAC technology that originated from early diagnostic work on ASTRA-1P — a prototype system designed to analyse real scan-line behaviour of products in free fall.

Rather than relying on a bulk channel that must periodically stop product flow, Hybrid Counting preserves single-file certainty while dynamically scaling the number of active channels according to product size and flow conditions. This allows the system to achieve bulk-like throughput without sacrificing deterministic counting accuracy.

The underlying ideas were first explored in the ASTRA-1P prototype. View the ASTRA-1P Museum entry →

Conceptual illustration of the Hybrid Counting principle with 4 counting channels and 3 governors, resulting in a 33% increased throughput.

Why it matters

Flexibility

Supports both standard and expanded channel configurations in the same machine.

Reduced complexity

A fixed number of governors avoids the need for one-to-one scaling with channel count.

Unchanged footprint

Higher throughput is achieved within the same machine envelope, avoiding the need for additional floor space compared to larger multi-channel machines.

Operational behaviour

Hybrid mode maximises throughput for smaller products.
A controlled handover ensures accurate final counts.
System behaviour is deterministic and operator-transparent.

Modular by design

The system can be reconfigured between channel modes using modular hardware components and a simple HMI selection, making it practical for a wide range of tablet and capsule sizes.