Inspection systems for printed corrugated packaging

  • Optimize print quality
  • Reduce production costs
  • Improve customer satisfaction
CartonSTAR

Maximizing print quality on corrugated packaging

Corrugated carton board

Corrugated board packaging is considered to be particularly sustainable and is becoming increasingly important in the packaging industry. At the same time, the requirements for the design of displays such as shelf-ready trays, advertising displays or outer packaging made of corrugated board are increasing. Multi-colour printing with complex decorations in flexographic printing or small, possibly even personalized print series in digital printing processes challenge print shops to achieve the perfect quality of the printed image and at the same time reduce quality costs. With its inline print image inspection systems, ISRA VISION also offers you solutions for quality control in the various printing processes. 

Flawless flexo printing

Discover the solution for print inspection on printed corrugated board using the flexographic printing process - CartonSTAR. The increasing demands on print quality are a key factor for a convincing shopping experience at the point of sale. Printing errors such as missing colors, inaccurate register, streaking, splatters, stains or faulty barcodes and QR codes can lead to waste and increase production costs.

Inspection begins with CartonSTAR even before the actual printing process starts. The future print image can be compared with a PDF file approved by the customer as early as the make-ready stage. In this way, errors such as incorrectly inserted or damaged printing plates become visible in advance and can be rectified before misprints occur.

However, the inspection of corrugated board poses further challenges, such as the detection of pseudo defects due to the uneven surface of the plates. Thanks to special algorithms, CartonSTAR detects these "false defects" and compensates for them.

During the printing process, the LiveSheetView function ensures that the operator can observe the printing process even more closely using precise live images. The print image currently being inspected is displayed on a separate monitor. It is possible to zoom in and out of the current image at various zoom levels in order to take a closer look at specific areas during ongoing production. The image size corresponds to the length of the print panel and the width of the material.

As a general rule, not every defect is a reject. Depending on the type or position of the defect, these can sometimes be tolerable. With defect classification, ISRA VISION offers a further function for checking the print quality and only displaying relevant defects.

For defective sheets, however, the finishing line is reached at the end of the printing process. Thanks to CartonSTAR, they are ejected and are therefore no longer part of the finishing process.

Benefits

  • "Open architecture" - full flexibility in terms of the required detection functions (resolution, color, etc.) 
  • Customization options for unique printing applications (holographic, etc.)
  • Reduction of waste and customer complaints
  • Precise inline inspection of the print job at maximum machine speed
  • High form factor with a high degree of freedom to fit into any machine on the market
  • High efficiency and long-life LED lighting for years of maintenance-free operation
  • Earliest detection of systematic printing errors
  • 100% detection of sporadic errors
  • Substrate compensation to avoid false alarms
  • Automatic ejection of defective panels
  • Advanced defect classification 
  • Job management for different quality levels; adjustable quality parameters
  • Verification of the correct print job and control of the printing plates by comparison with the customer PDF
  • Control of static barcodes and QR codes
  • LiveSheetView for viewing the job currently being printed
  • Stripes
  • Register defects
  • Splashes
  • Contamination
  • Color deviation
  • Missing print
  • Non-readable, static bar or QR codes

Download additional information

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Model AG ensures zero-defect carton board packaging

Read how the Swiss packaging producer Model AG optimizes quality assurance and transparency in carton board packaging with the CartonSTAR and PaperMASTER inspection systems. The systems ensure precise defect detection, classification and continuous monitoring, reducing production downtime and increasing customer satisfaction. Find out how the systems offer maximum reliability and help Model AG to achieve zero-defect production and increase overall packaging quality.
 

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DS Smith enhances corrugated board quality and sustainability

DS Smith, a leader in corrugated board packaging, achieves superior print quality and sustainability with CartonSTAR. The two-camera solution with high-performance LED illumination distinguishes quality-relevant defects, ensuring optimized production, reduced complaints, and a more sustainable use of resources. Read the success story to find out how CartonSTAR's defect classification function enables quick adaptation to customer-specific quality requirements and thus contributes to DS Smith's commitment to outstanding quality in corrugated board packaging.

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Digital printing

The demand for digitally printed corrugated board is constantly increasing. The big advantage of digital printing is the small batch sizes and the ability to personalize packaging more and more. This offers marketers many advantages for their campaigns. However, quality control is a decisive factor in keeping production costs stable, especially for small productions. In addition, digital printing processes are subject to special defects that are unique to this technology, such as streaking caused by clogged nozzles. For ISRA VISION, however, print image inspection is more than just the detection of nozzle streaks.

The inspection systems of the DigiSTAR series are specially designed for the detection of printing defects in digital printing. They check for all types of print defects: splashes or soiling, streaks, missing print image, color deviations and even detect defects that are difficult to see, such as banding. They also check the legibility of variable barcodes and QR codes.

The defect classification allows defects to be categorized as saleable goods or waste and also provides precise reporting on the defects found.

Whether you have your corrugated board printed using the sheet-fed or roll-to-roll process, there is a suitable system for every application.

The LiveSheet or LiveWebView function also shows the currently inspected panel on a separate monitor in digital printing and allows the operator to zoom in on specific areas.

In the roll-to-roll process, the ISRA systems are able to simultaneously inspect adjacent print images - so-called "panels" - of different lengths.

In the sheet-fed process, defective plates are ejected at the end of the printing process. In the roll-to-roll process, comprehensive reports and statistics provide information on defects, which can then be removed in downstream processes. 

Benefits

  • Reduction of waste and customer complaints
  • Precise inline inspection of the print job at maximum machine speed
  • Earliest detection of systematic printing errors
  • Comparison with an approved PDF file before printing begins
  • Defect classification
  • Checking the readability of variable barcodes or QR codes
  • LiveWebView / LiveSheetView
  • Ejection of faulty sheets at the end of the printing process
  • Simultaneous inspection of several adjacent panels with different lengths (roll-to-roll method)
  • Comprehensive Reporting of sheet or roll quality
  • Splashes
  • Banding
  • Nozzle streaks
  • Non-readability with variable bar- or QR codes

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

Print production analyzed: Identify potential cost savings

Our technical article explains how production analytics software helps to identify potential cost savings. Our technical article explains how production analytics software helps to identify potential cost savings. Practical case studies clearly show how the analysis of existing data indicates quality deficiencies and thus helps to develop appropriate solutions.

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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