Plastic film, foil & sheets inspection

  • Reduction of quality complaints and costs
  • Document quality and ship with certainty
  • Optimize maintenance 
  • Quickly resolve resin issues and process upsets
  • Optimize converting and disposition decisions
  • Fast ROI through a short setup time
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Defect-free plastic film, foil & sheets

Our proven solutions for quality inspection of plastic films, foils, and sheets offer our customers numerous advantages. They ensure the desired functionality and appearance of the product as well as your customer’s quality requirements resulting in increased confidence and customer satisfaction. Fast setup time provides a fast ROI, through increased production due to reduced waste.

Flexible Packaging & Converting

Film Roll slitting machine ; a shearing operation that cuts a large roll of material into narrower rolls

Defects in the production and converting of films used for flexible packaging or in converting stages can endanger the appearance and product safety. Holes, gels, contamination, coating, and laminating defects cause functional defects in the packaging. Contamination or other surface imperfections can affect the appearance of the packaging and reduce consumer confidence in the product.

The SMASH automatic quality inspection system reliably identifies all defects during production before they affect the appearance or lead to product safety issues.

During film production, the self-learning QuickTeach function automatically classifies defects and surface properties. In the cloud-based version of the feature, an AI-based cluster segments the defects autonomously and enables the processing of large amounts of data. 

With the help of an advanced lighting concept, every defect, regardless of its size, is detected in this production step and further classified based on each user’s requirements. Serious defects can be flagged or marked while all defects are classified and mapped. Haze can be monitored and the entire film surface is uniformly checked for homogeneity.

The operator easily splices defects out with the RewindManager function that stops the slitter or doctor machine at the location of critical defects for removal. Converting Optimization software allows a finished roll cut layout to segregate the defects and data for each finished slit roll that can be automatically graded as pass/fail based on that finished roll’s defect content.

Benefits

  • Reduce scrap and energy consumption by up to 10%
  • Improve customer satisfaction
  • Optimized maintenance and downtime
  • Certify final quality – put a 100% seal of quality on your products
  • Increase throughput, optimize your process
  • Document incoming resin quality
  • Film production: QuickTeach, advanced illumination concept, edge detection, homogeneity inspection
  • Converting: rewind manager, slit optimization, quality review, grading options for daughter-rolls
  • Coating Defects 
  • Contamination
  • Delamination
  • Edge defects 
  • Fish eyes
  • Gauge variation
  • Gels
  • Hazing
  • Holes
  • Missing layer 
  • Oil spots
  • Scratches  
  • Die lines
  • Static buildup
  • Streaking
  • Voids/skips  
  • Wrinkles and creases

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Optical Film

Producing optical prism films, polarizer films, protective films, and window films requires extreme care and precision. The goal is to ensure the flawless quality of the products coated with them - from simple glass to complicated electronic circuits.  

During the production of optical films, critical defects can degrade polarization, reflectance, and transmission properties. These include harley bear defects, scratches pinholes, haze, coating, polarization defects, as well as oil spots, structural defects, and inhomogeneity.

The automatic SMASH surface inspection system detects even the smallest defects of optical films in real time. Line scan cameras ensure inspection at web speeds of approx. 10-100 m/min while maintaining the highest image resolution.

For optical film inspection, it is equipped with an automatic polarizer filter, which automatically adjusts the polarization angle. It sets the polarizer to full light extinction or to other predefined settings. As all settings and adaptations can be done online or automatically there is no need to stop the production for these adjustments. The lens also captures special defects like harley bear, which are not visible without such a filter. In addition, the inspection is complemented by advanced detection of scratches, another common, serious defect in optical films. 

Customized lighting supports the reliable detection and intelligent classification of defects that remain hidden from the human eye. As a result, conclusions can be drawn about causes or faulty process parameters, which can then be continuously monitored and optimized. 

Benefits

  • Optimized optical layout for low cost
  • Process optimization
  • Virtual defect classification to raise production yield
  • Precise quality inspection at high web speeds
  • SMASH+ for data combination
  • Defect classification (QuickTeach)
  • Defect data combination
  • 3D data (Z sensor)
  • Rewind manager
  • Advanced scratch detection
  • Auto polarizer adjustment
  • Scratches
  • Dent
  • Bubble
  • Harley bear
  • Hazing 
  • Coating defects
  • Oil stains
  • Polarization defects
  • Inspect at a web speed of approx. 10-1000 mpm

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PVB interlayers

Closeup frameless laminated glass balcony railing.

PVB interlayers are an important component of safety glass used in various applications such as architectural glass, automotive windshields and head-up displays (HUD), and cruise ship glazing. Defective interlayers can lead to consequential delamination as well as discoloration in the laminated safety glass.

With state-of-the-art sensor technology and innovative software tools, the SMASH surface inspection system inspects PVB webs up to 3 meters wide on the fly. 

The system detects and classifies even low-contrast defects in each process step in real time. The inline inspection system enables precise differentiation between surface conditions and actual defects.

By intervening directly, the operator can eliminate sources of error and reduce scrap. This ensures that only defect-free PVB film is delivered to the end customer. Complete documentation of all material properties also supports the successful performance of all customer audits.

Benefits

  • Elimination of sources of error 
  • Reduction of rejects and increase of saleable production quantity 
  • Dispatch only flawless material to the end customer
  • Seamless monitoring of product properties
  • QuickTeach
  • Gels
  • Carbon
  • White spots
  • Clear spots 
  • Plasticizer drops
  • Color band defects
  • Missing surface pattern 
  • 3 m width, typically approx. 15 m/min

OEMs gain edge with integrated inspection

As a leading vision solutions provider and partner to global manufacturers, we understand the challenges machine and plant builders face when designing complex production lines. With state-of-the-art inspection technology seamlessly integrated into your extrusion line, you can offer your end-customers significant benefits, such as easier implementation, time and cost savings, space savings, easier operation, avoidance of potential compatibility issues, increased efficiency, and reduction of the need for complicated retrofits.

By equipping your extrusion line with state-of-the-art inspection technology, you offer your customers decisive advantages and secure a significant competitive edge for yourself. 

With our SurfaceSTAR product series, designed specifically for OEMs, we offer plug-and-play web inspection systems that integrate seamlessly into your extrusion lines. 

The SurfaceSTAR SIS (Surface Inspection System) includes high-quality embedded cameras and proven lighting technology that ensure maximum performance and reliability in defect detection. Advanced SMASH software and a user-friendly, browser-based Touch & Inspect graphical user interface further enhance the system's capabilities. With SurfaceSTAR SIS, your production system is capable of detecting defects as small as 150 µm, ensuring the highest level of quality control.

Our SurfaceSTAR GS (Gel Sensor) is a compact and efficient sensor unit designed to monitor gels and black spots during plastic film production. Direct communication between SurfaceSTAR GS and the PLC process control system creates a closed loop control system that immediately detects defects and forwards them to the process control system. This enables rapid response and regulation of temperature variations during extrusion. This prevents faulty production and leads to cost savings.

By integrating our vision solutions into your extrusion line, you can increase performance, efficiency and customer satisfaction. You'll offer your customers the benefits of smart, simple and excellent quality control - right from the start. In addition, our special OEM pricing gives you a cost advantage that increases the overall value proposition for your end customers.

Benefits: You as an OEM

  • Competitive advantage
  • Attractive pricing
  • Increased customer satisfaction
  • Plug & Play concept
  • Off the shell

Benefits: Your Customer

  • Seamless integration
  • Time and cost savings
  • Efficiency gains
  • Space savings
  • Easier operation
  • Cost savings
  • Increase in competitiveness
  • Reduction of the reject rate
  • No complicated retrofitting
  • Seamless, efficient and quality-oriented manufacturing

SurfaceSTAR SIS:

  • Scratches
  • Streaks
  • Additive drops
  • Oil drops
  • Holes

SurfaceSTAR GS: 

  • Gels
  • Black specs

SurfaceSTAR SIS:

  • From 200 to 1600 mm in width
  • Other widths on request according to the requirement profile

SurfaceSTAR GS:

  • OPC UA interface/OPC compatible as well as MQTT
  • 400 mm field of view
  • Monitoring of defects to 100 µm

Production analytics - Data-driven efficiency

The web-based production analytics platform allows you to check the system status of all production lines at a glance or analyze production data in detail. With the quality management system, you analyze historical data, monitor current inspection data in real-time, and identify future trends in your production process.

Early detection of production defects

Detect and quickly identify the cause of threshold value violations at every stage of production with live status information and automatic alerts. As a result you can quickly resolve production defects, shorten downtime, and reduce production costs.

Predictive maintenance

You can prevent potential system failures by analyzing real-time data from the sensors and monitoring systems. This allows proactive planning of maintenance, based on the actual condition of the machines, instead of following a fixed schedule. This data-driven approach saves costs through reduced downtime and increased overall productivity, as well as longer production line life. 

Optimization of production

Dashboards allow you to compare production line and product data onsite or remotely, providing key insights for optimization. This enables you to make informed professional decisions along your value chain to increase the product quality as well as profitability. You can continuously track the progress of optimization measures and present them with visualized advanced reports.

Your benefits

  • Time-saving multi-line overviews, one view for all quality-related information
  • Minimize downtime by monitoring system health data
  • Faster reaction to quality issues with quality data monitoring
  • Fast elimination of production defects, reduction of production costs
  • Improved maintenance for reduced downtime, higher overall productivity and longer production line life

Key Features

  • Overview on production data and plant status
  • Live insights from real time data
  • Department oriented dashboards, customer specific adaptations are possible
  • Web-based solution, no client software installation required
  • Threshold monitoring and alerting
  • Open to integrate relevant third-party data and export data to the customer's systems

Service solutions and individual trainings

For the efficient and future-proof operation of your production systems our highly qualified service teams support you globally in all matters. We provide the implementation, maintenance and servicing as well as the analysis and optimization of your systems.

Learn in the ISRA VISION Academy how our competent trainers always keep your employees up to date with the latest knowledge so that system operators, product engineers and quality managers become real inspection experts.

Contact our experts

Bünyamin Camgöz
Surface & Print inspection - Advanced Materials

Albert-Einstein-Allee 36-40
45699 Herten
Germany

Phone: +49 / 2366 / 9300-284

E-Mail: [email protected]

Buenyamin Camgoez