This page shows all inspection solutions for flexible packaging

Flexible packaging

Inspection solutions for flexible packaging


  • Maximum throughput of saleable products in metal sheet decoration
  • Optimized process from printing to finishing
  • More sustainable production
  • Less waste and lower total cost of ownership

Mastering the challenges of printing on flexible packaging

High-quality packaging not only stands for aesthetic appearance but is also rated by the end consumer as an indication of the quality of the packaged product. Flexible packaging manufacturing is therefore a complex process that presents critical challenges. The most common problems include print quality defects, sealing, coating, or lamination defects. 

Other challenges include waste management and cutting production costs while maintaining high-quality standards. Overcoming these problems requires great attention at every stage of the production process. 

From printing to finishing, precise quality control must ensure that the final product meets the desired quality standards. An automated inspection system, therefore, is the solution to reduce waste and save costs and time.  

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Learn how 100%inline inspection increases uptime, reduces waste, and saves resources.

Minimized Make-Ready times, a perfect view of the web, and everything in the register

There are many things to consider when setting up the printing process - and time is short. In the make-ready process, the course is already set to avoid waste: Incorrectly inserted or defective printing plates, wrong text, and language versions can already be identified and corrected before printing starts by comparing the Golden Master with the reference PDF file released by the customer. 

In addition, the printing units are set in the register. The automatic register control in the ViewSTAR web viewing system takes over the setting of the printing units here. With web viewing, printers can optionally check individual print points in high resolution or get an overview.

The ViewSTAR viewer monitors even the finest printing characteristics and color tone fluctuations with the highest resolution and color and offers web monitoring at a high level during the further printing process. 

During the printing process, the LiveWebView feature of the PrintSTAR inspection system enables operators to monitor the print process in even more detail thanks to precise live images. The inspected printed image is displayed on a separate monitor; users can then zoom in and out of the current image to take a closer look at specific areas while production is still in progress. The image size corresponds to the length of the repeat and the material width.

This not only minimizes printing errors and unnecessary contamination on the roller but also assists the operator during the make-ready process. The uninterrupted insight into the press granted by LiveWebView can be used to monitor register behavior – making the costly and time-consuming process of stopping the printing press for fine-tuning outdated.

Benefits

Higher level of automation in the Make-Ready process leads to savings in material costs and working time

Uninterrupted insight into the press granted by LiveWebView

Features, typical defects and technical data

Features

  • Digital Assistance to extend the inspection capabilities of the basic setup: for PDF verification 
  • Register Control 
  • Web Viewing 
  • LiveWebView 

Typical defects

  • Wrong ink setup or plate order (ink or plate in wrong printing unit) 
  • Wrong printing plates/cylinders (wrong layout) 
  • False text or language versions 
  • Wrong job version 
  • Defective printing plates/cylinders 

Technical data

  • Inspection width: from 600 mm up to 2500 mm; others on request

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Take control of the printing quality

The steadily increasing demand for brilliant print quality with short turnaround times and competitive prices poses challenges for the flexible packaging printing industry. To ensure high image quality, our automated inspection systems reliably detect repeated or sporadic defects. A sophisticated qualifier allows these defects to be classified, distinguishing serious from negligible defects.  With real-time monitoring and appropriate alarms for serious defects, operators can intervene in the printing process at any time to eliminate the sources of error or adjust the process. Stripes, streaks, splashes, missing print images, or contamination are thus quickly detected. 

Even for hard-to-detect toner errors, so-called hazing, (also known as scumming or fogging), there are inspection solutions. Hazing is a slight and even ink transfer in non-image areas caused by a doctor blade, cylinder, or ink. On transparent substrates, the defect is invisible to the operator and is only detected in the downstream production workflow. As a result, the material showing the defect must be scrapped and reprinted. Overall, our inspection solutions help avoid costly misprints and ensure that the final product meets the highest quality standards.

Benefits

100% print inspection in full coverage, anywhere and any time

Classification allows for detecting only relevant defects

Detection of sporadic and/or repeating print defects, which helps your operator to react fast

Higher sustainable production processes as waste production can be avoided from an early start

Features, typical defects and technical data

Features

  • Hazing detection 
  • Streak Detection 
  • Analyze your production process with our data mining software EPROMI to make the correct decisions 

Typical defects

  • Splashes & spots 
  • Missing ink 
  • Hazing 
  • Register errors 
  • Streaks and drags 
  • Dirt 

Technical data

  • Inspection width: from 600 mm up to 2500 mm; others on request
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Learn how Südpack profits from our advanced hazing detection solution.

Learn how G'Imprim enhanced their quality in packaging film printing.

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Always in the right color

The correct color is one of the most essential attributes for quality in packaging. High color consistency and also continuous color measurement and control are crucial. Whether flexible packaging, personal care products, or labels - brand manufacturers allow only minor color tolerances because perfect packaging and uniform coloration are integral parts of the brand promise.

Maintaining the correct color and in line with the color values (L*A*B) is an important task during the printing process. The PrintSTAR inspection system offers the ColorWatch function to keep track of this with a relative measurement.

Without any additional hardware, the RGB line scan cameras can be used to detect color deviations from a reference image. DeltaE values are measured and continuously displayed. Any desired location can be measured, also solid or halftone. 

An enhancement to this is offered by the absolute color measurement by ColorSTAR, which ensures a constant measurement and monitoring of the absolute color values (L*a*b*).

Benefits

Suitable for all substrates, even transparent foil

Unique concept for color management: measure anywhere and anytime, in as many areas in each repeat as needed

Real-time measurement gives the best possible feedback to reduce make-ready time and save costs

Indefinite number of measurement positions

Reduce waste and cut-out samples

Features and typical defects

Features

  • ColorWatch for relative color measurement 
  • ColorSTAR inline color measurement for maximum color accuracy 
  • Spectrophotometer according to color measurement standards 
  • Automatic and continuous tracking of measurement positions for all kinds of material, even for thin material with stretch, without any need for additional track equipment 
  • Simultaneous color deviation across the whole line width 
  • Report and monitor dot gain and density 

Typical defects

  • Color deviations
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Absolute Color Measurement: Intelligent systems ensure seamless quality control.

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Keep your cold-seal intact and in register

Cold seal

Cold-sealed packaging offers packagers many advantages: fast distribution and adhesives adapted to the specification of the application and packaging ensure both high process speeds and different bond strengths.  However, sealing defects such as missing seals or contamination of the adhesive can quickly destroy these advantages. By using inline inspection systems, these defects can be detected and eliminated as quickly as possible. Another crucial point in packaging with a cold seal is the register accuracy of the front and back. Here, a special ISRA technology is used: 

The PrintSTAR system simultaneously inspects both the front and back of the substrate with a superimposed image. If the sealing layer on the reverse side does not match the print image on the front side exactly, an acoustic signal alerts the operator immediately.

An additional advantage of the groundbreaking inspection is that register marks - which slow down the process - can be eliminated, reducing the required film width and saving material costs.

Benefits

Less waste

No need for register marks

Features and typical defects

Features

  • Continuous front-to-back registration

Typical defects

  • Contamination 
  • Missing sealant 
  • Chunks 
  • Front-and-back registration defects 
premium header flexible packaging

Learn how PrintSTAR supports a producer of flexible packaging with their cold seal application .

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Flawless quality of varnish Protective and decorative varnishing

Varnish defects

Varnishes provide a noble finish, special effects, or protection in the printing process. Whether simple embossing, gloss, or soft-touch effects or incorporated silver and gold pigments, special effects must be 100% flawless to ensure the distinctive quality and value of the printed product. Besides that, the system can also inspect overprint varnish, which is needed on special occasions.

PrintSTAR offers a 100% inline inspection that provides a comprehensive and reliable inspection of varnish defects on both the front and back sides of the web. For this purpose, the system uses permanently installed image capture units with fast, high-resolution line scan cameras and special, ultra-bright LED illumination.

Benefits

Defect detection in a wide range of coating and lamination techniques

Checking of register accuracy

Continuous and complete process control

Typical defects and technical data

Typical defects

  • Scratches 
  • Splashes 
  • Smudges 
  • Uneven coating 

Technical data

  • Inspection width: from 600 mm up to 2500 mm; others on request

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Perfect coatings & lamination for printed flexible packaging

Coating and lamination

During lamination, films can have various types of defects, such as wrinkles, inclusions, bubbles, and foreign objects. Detecting these defects, some of which are very small, with the bare eye can be difficult. In addition, manual inspection is subjective and depends on the experience and expertise of the inspector, leading to inconsistencies in defect detection. 

Another critical challenge is that films are often produced at high speeds, requiring fast and accurate inspection. 

So better be on the safe side! Hand over quality control to our automatic inspection systems. They secure the fastest image capture rate in the industry and reliably detect all typical defects that can occur during the lamination process.

Our seamless inline print inspection system inspects webs simultaneously from the top and bottom. The system thus simultaneously detects defects on the front and backside, for a variety of coating and lamination techniques. Finally, our system guarantees continuous and seamless process control, covering the print image, lamination, and coating. 

Benefits

Detection of all typical lamination defects

Continuous and seamless process control

Features, typical defects and technical data

Features

  • Coating and lamination inspection 
  • Permanently installed image acquisition units 
  • Fast, high-resolution line scan cameras 
  • Ultra-bright LED illumination 

Typical defects

  • Wrinkles 
  • Inclusions 
  • Bubbles 
  • Contamination 
  • Delamination 
  • Missing coating 

Technical data

  • Inspection width: from 600 mm up to 2500 mm

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Guaranteed quality for all converting and slitting processes

At the end of the production chain, there is further processing with various process steps such as wrapping or cutting. For these tasks, too, high quality is the be-all and end-all: the knives must be set to the right widths, and the roll density and tension must be optimal so that no problems occur. Another complicating factor is that both unprinted and printed films are often processed on the same machine.

We offer inspection systems that can inspect both unprinted and printed substrates. Equipped with features such as the RewindManager, which automates the removal of waste. 

By linking to a synchronized database, the user can select which defects to remove. This allows the manufacturer to maximize the value of a production roll. To complete the production process, the last steps are also monitored. 

The PrintTrack function monitors the web for stretch. It alerts the operator when a threshold is exceeded and conveniently displays this in a trend graph. The Web position is monitored so that knife positions can be adjusted for the cutting process, resulting in less waste and higher quality. 

Benefits

Removal of defects in each roll

Longer machine running times

Highest quality for all converting processes

Reduction of waste

Maximum production efficiency

Features

  • Automatic removal of waste in the finishing department 
  • Inspection of a printed and unprinted film with one single system 
  • ReWind Manager 
  • Monitoring of web stretching  

Customer service & training

Service

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 - quickly, reliably, 24/7. 

Visit our service center and request your customized service solution. 

Furthermore, 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.

Visit our ISRA VISION Academy and book your individual and scalable trainings.

Contact us

Bünyamin Camgöz

Surface & Print inspection - Advanced Materials

Albert-Einstein-Allee 36-40
45699 Herten
germany