Inspection solutions for flexible packaging

  • Maximized sales of saleable products
  • Optimized process from printing to finishing
  • More sustainable production
  • Less waste and lower total cost of ownership
Flexible packaging

Top quality from printing to finishing

Ensure smooth control of all process steps with the automated handling of all components - large or small, sorted, or unsorted. Reduce your quality costs with reliable inspection solutions. 

By integrating our systems into your process, you can fully automate a wide range of part variations and easily maintain specified tolerance limits. This significantly improves process quality and ensures that industrial robots can be used with ease.

With over 35 years of experience in the industry, we have developed a deep understanding of our customers' requirements and have optimized our systems specifically for body shop applications. 

Complete print inspection for flexible packaging excellence

Explore how ISRA VISION's PrintSTAR, ColorSTAR, ViewSTAR, and DualSTAR systems optimize flexible packaging inspections. Achieve 100% inline precision, reduce waste, and enhance resource efficiency. From detecting minute defects to ensuring color fidelity, these solutions streamline production, boost brand perception, and maximize quality. 

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Efficient make-ready & print quality control

Setting up the printing process (make-ready) requires attention to numerous details, and time is short. Measures are already taken during the make-ready process to avoid waste. By comparing the Golden Master with the reference PDF file approved by the customer, incorrectly inserted or defective printing plates as well as incorrect texts and language versions can be identified and corrected even before the actual printing begins. Smooth setup of the print job and fast, flawless operation of the press significantly reduce the production of unsaleable material in the makeready process. Automated quality controls, supported by the PrintSTAR inline inspection system, offer opportunities for cost savings and time optimization in this step.

During the make-ready process, the printing units are precisely set in register to achieve a perfect, overlapping result. These work steps can also be automated. For example, the ViewSTAR web monitoring system automatically adjusts the printing units. As the printing process continues, the web monitoring system enables the printers to check individual printing points in high resolution or to view the currently printed image. The ViewSTAR viewer monitors the finest print characteristics and color variations with the highest resolution and color fidelity, providing precise web monitoring throughout the printing process.

During the printing process, the LiveWebView function of the PrintSTAR inspection system enables the operator to monitor the process in even greater detail with precise live images. The inspected print image is displayed on a separate monitor, allowing the operator to take a closer look at specific areas during production. The image size adapts to the length of the panel and the width of the material, meaning that printing errors or soiling on the roller are detected as early as possible and can be rectified. The uninterrupted view of the press provided by LiveWebView can be used to monitor register behavior. Costly and time-consuming stopping of the press for fine adjustment is no longer necessary.

Benefits

  • Higher degree of automation in the make-ready process leads to savings in material costs and working time
  • Monitoring the printing process thanks to precise live images
  • Comparison of the print image with the Golden Master (QuickProof) 
  • Automatic register setting (RegisterControl)
  • LiveWebView 
  • Incorrect ink setting or printing plate arrangement (ink or plate in the wrong printing unit)
  • Incorrect printing plates/cylinders (incorrect layout)
  • Incorrect text or language versions
  • Incorrect job version
  • Defective printing plates/cylinders
  • Register errors during the set-up process
  • Inspection width: from 600 mm up to 2500 mm; others on request

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ViewSTAR flyer de

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Control the print quality

The ever-increasing demand for brilliant print quality with short throughput times and competitive prices poses challenges for the flexible packaging printing industry. To ensure high image quality, our automatic inspection systems reliably detect recurring or sporadic defects. Sophisticated qualification makes it possible to classify these defects. The classifier distinguishes between serious and negligible defects.  Thanks to real-time monitoring and corresponding alarms for serious defects, the operator can intervene in the printing process at any time to eliminate the source of the defect or adjust the process. Stripes, streaks, splashes, missing print images or contamination are quickly detected. 

Inspection solutions are also available for toner defects that are difficult to detect, known as hazing (also known as scumming or fogging). 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 process. As a result, the material with the defect must be scrapped and reprinted. Overall, our inspection solutions help to avoid costly misprints and ensure that the end product meets the highest quality standards.

Barcodes and QR codes are now standard on flexible packaging and offer benefits to the consumer or in the sales process. It is crucial that these codes are legible at all times to ensure smooth usage. Unreadable codes are unacceptable and must be avoided. Intelligent inspection systems such as PrintSTAR are able to identify codes with static content and check their legibility. If a code is unreadable, the system triggers an alarm that informs the operator. The operator can then identify and eliminate the causes of illegibility, such as missing print images, ink splashes or other contaminants. This ensures that the codes always work correctly and fulfill their intended functionality.

Benefits

  • 100% print inspection in full coverage, anywhere and any time
  • Detection of sporadic and/or repeating print defects, which helps your operator to react fast
  • More sustainable production processes as waste production can be avoided from the start
  • Classification allows for detecting only relevant defects
  • Hazing detection 
  • Streak Detection 
  • Reading out static codes
  • Analyze your production process with our data mining software EPROMI to make the correct decisions 
  • Splashes & spots 
  • Missing ink 
  • Hazing 
  • Register errors 
  • Streaks and drags 
  • Dirt 
  • Missing print image or contamination on barcodes or QR codes
  • Inspection width: from 600 mm up to 2500 mm; others on request

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PrintSTAR flyer en

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SÜDPACK Bioggio achieves sustainable excellence with PrintSTAR's Advanced Hazing Detection

In the pursuit of quality and sustainability, SÜDPACK Bioggio transforms its flexible packaging production. The PrintSTAR Advanced Hazing Detection system prevents elusive defects, ensuring 100% verified quality. ISRA VISION's technology accelerates workflows, reduces defects, and slashes customer complaints, marking a pivotal shift towards sustainable, efficient, and high-quality packaging solutions.

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G’Imprim elevates printing precision and packaging quality

Discover how G’Imprim, a prominent flexible packaging printer in France, achieved highest printing precision and quality using our PrintSTAR inspection solution. Equipped with high-resolution line cameras and ultra-bright LED lighting, the system ensures real-time defect detection, classification, and early rectification. The result? Reduced waste, saved time and money, and a significant drop in customer complaints, marking a transformative leap towards error-free, sustainable printing solutions.



 

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Always the right color

Accurate color reproduction is one of the outstanding features of high-quality packaging. Constant color consistency and continuous color measurement and control are of crucial importance. No matter what type of packaging is involved: Brand manufacturers tolerate only minimal color deviations, as flawless packaging and consistent coloring are essential components of their brand promise.

Monitoring correct color reproduction and color values (L*A*B) is a key task during the printing process. With its ColorWatch function, the PrintSTAR inspection system makes it possible to ensure this through relative measurements.

By using RGB line scan cameras, color deviations from a reference image can be detected without the need for additional hardware. DeltaE values are measured and displayed continuously and any location, including solid or halftone, can be measured. An additional option is absolute color measurement with ColorSTAR, which ensures continuous measurement and monitoring of absolute color values (L*a*b*).

Benefits

  • Suitable for all substrates, even transparent foil
  • Reduce waste and cut-out samples
  • Unique concept for color management: measure anywhere and anytime, in as many areas in each repeat as needed
  • Indefinite number of measurement positions
  • Real-time measurement gives the best possible feedback to reduce make-ready time and save costs
  • ColorWatch for relative color measurement 
  • ColorSTAR inline color measurement for maximum color accuracy 
  • Spectrophotometer according to color measurement standards 
  • Automatic and continuous tracking of the measuring positions for all types of material, even for thin material with stretching, without the need for additional tracking devices
  • Simultaneous color deviation across the whole line width 
  • Logging and monitoring of dot gain and density
  • Color deviations

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ColorSTAR flyer en

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ColorSTAR flyer de

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PrintSTAR flyer cn

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Absolute color measurement: Intelligent systems ensure seamless quality control

Discover how ColorSTAR ensures absolute color consistency in the printing of fexible packaging. The cutting-edge technology, integrated into the PrintSTAR inspection system, provides continuous, real-time color accuracy without stopping the printing press. The unique combination of line scan cameras and a spectrophotometer reduces make-ready times by up to 60%, significantly lowering costs.

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Cold sealing: Intact and in the register

Cold seal

Cold-sealed packaging offers packers a variety of benefits, including fast distribution and customized adhesives tailored to application and packaging requirements. This enables high process speeds and different bond strengths. However, sealing defects such as lack of sealing or contamination of the adhesive can quickly negate these benefits. The use of inline inspection systems enables these defects to be quickly detected and eliminated.

A crucial aspect of packaging with cold seals is the register accuracy of the front and back. This is where our special ISRA technology comes into play: the PrintSTAR system simultaneously inspects the front and back of the substrate using a superimposed image. If the seal layer on the reverse side does not exactly match the print image on the front, the operator is immediately alerted by an acoustic signal.

In addition, this innovative inspection solution enables the elimination of register marks, which can slow down the process. This reduces the required film width and therefore saves material costs.

Benefits

  • Less waste
  • No need for register marks
  • Continuous front-to-back registration
  • Contamination 
  • Lack of sealing
  • Lumps
  • Register errors on the front and back

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PrintSTAR flyer en

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Cold Seal Inspection: Enhancing packaging quality

Read how a medium-sized flexible packaging manufacturer overcame the challenges of sustainable production with PrintSTAR Cold Seal Inspection. This innovative solution ensures uniform coating, detects defects in real time and maximizes output while reducing material waste. In addition, the system's audio alert feature improves operator control, and the data collected enables continuous process improvement for greater efficiency and cost savings.

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Perfect quality of all types of vanishes

Varnish defects

Varnishes give printed products a high-quality finish, provide special effects and protect during the printing process. Whether it is simple embossing, gloss or soft-touch effects or incorporated silver and gold pigments, special effects must be 100% flawless to ensure the unique quality and value of the end product. In addition, overprint varnishes required for special occasions can also be tested.

PrintSTAR offers 100% inline inspection, providing a thorough and reliable inspection of coating defects on both the front and back of the web. The system uses fixed image capture units with fast, high-resolution line scan cameras and special, ultra-bright LED lighting.

Benefits

  • Checking of register accuracy
  • Continuous and complete process control
  • Defect detection in a wide range of coating and lamination techniques
  • MultiView
  • Scratches 
  • Splashes 
  • Dirt
  • Uneven coating 
  • Inspection width: from 600 mm up to 2500 mm; others on request

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PrintSTAR flyer en

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PrintSTAR flyer de

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Ensure flawless coatings & lamination

Coating and lamination

During the lamination process, films can exhibit various types of defects, including wrinkles, inclusions, bubbles and foreign bodies. Detecting such defects, some of which are very small, with the naked eye is often difficult. In addition, manual inspection is subjective and depends heavily on the experience and expertise of the inspector, which can lead to inconsistencies in defect detection.

Another critical challenge is that films are often produced at high speed, which requires fast and accurate inspection. It is therefore advisable to play it safe! 

Leave the quality control to our automatic inspection systems. They offer 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 above and below. As a result, the system detects defects on the front and back simultaneously and is suitable for a wide range of coating and lamination techniques. Finally, our system guarantees continuous and seamless process control that comprehensively covers the print image, lamination and coating.

Benefits

  • Detection of all typical lamination defects
  • Continuous and seamless process control
  • Inspection of coatings and laminations
  • Permanently installed image acquisition units
  • Fast, high-resolution line scan cameras
  • Ultra-bright LED lighting
  • Folds
  • Inclusions 
  • Bubbles 
  • Contamination 
  • Delamination 
  • Missing coating 
  • Inspection width: from 600 mm up to 2500 mm

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PrintSTAR flyer en

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PrintSTAR flyer de

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PrintSTAR flyer cn

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Guaranteed converting and slitting quality

When it comes to further processing at the end of the production chain, with process steps such as winding or slitting, outstanding quality is crucial. Precise adjustment of the slitter width, optimum roll density and tension are essential to avoid problems. This becomes particularly challenging when both unprinted and printed films are processed on the same machine.

Our inspection systems are designed to inspect both unprinted and printed substrates in a single system. Equipped with functions such as the RewindManager, which enables the automated removal of waste. 

By linking to a synchronized database, the user can select which defects should be rectified to maximize the value of a production roll. In addition, we also monitor the final steps of the production process.

The PrintTrack function monitors the web for stretch and alerts the operator if a threshold value is exceeded. This is conveniently displayed in a trend graph. We also monitor the web position so that the knife positions can be adjusted for the cutting process. This results in less waste and higher quality end products.

Benefits

  • Elimination of faults in every roll
  • Longer machine running times
  • Highest quality for all converting processes
  • Maximum production efficiency and quality
  • Reduction of rejects
  • 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  

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