This page shows all inspection solutions for metal sheet decoration

DecoSTAR

Optimum throughput of saleable products when decorating metal sheets


  • Maximum throughput of high-quality products
  • Enhanced quality of metal sheet printing
  • Reduced waste and increased yield
  • High level of customer satisfaction

Top grade metal printing at maximum production speed

The printing of metal sheets is a complex process that places high demands on printing, coating and material integrity. A whole range of error sources, such as colour deviations, printing errors, impurities, edge defects and material defects, can significantly affect the quality of the end product. However, one of the biggest challenges is to achieve high product quality at a high production speed. 

Our solutions for inline print and coating inspection ensure both 100% quality control and process optimisation at maximum throughput. ISRA inspection systems are suitable for both offset and digital printing technology.

High-quality metal printing on steel and aluminium sheets

Reliable quality control for metal printing on steel and aluminium sheets is guaranteed by the DecoSTAR EVO inline print inspection solution. The flexible, easy-to-install system can be used for tinplate or aluminium as well as for high-gloss or matt motifs on any type of machine in both offset and digital printing. With highly efficient LED lighting, the system reliably identifies colour deviations as well as edge and material defects.

In addition, with its intuitive multi-touch user interface, the system provides high-quality defect data that helps to eliminate serial defects and increase yield.

Not every defect means a rejection:

Defect classification software makes it possible to differentiate between relevant and irrelevant defects and increases the saleable quantity. Thanks to the latest camera technology, the inspection systems offer maximum performance. A modern graphical user interface ensures a high level of user-friendliness. 

Benefits

Offset & digital print inspection with the same system

Best resolution for detection capabilities (resolution, colour, etc.)

The most widely used inspection system in the metal packaging industry

Reduce waste and increase yield

High form factor with a high degree of freedom to adapt to any machine on the market

High efficiency and long-life LED lighting for years of maintenance-free operation

100% inline inspection for each sheet at maximum production speed

Intuitive set-up procedure for new jobs or use of repeat files

Continuous feedback on the printing process, reporting of serial errors, adjustable quality parameters

Versatile use: for tinplate or aluminium, high-gloss or matt motifs on all machine types

Features, typical defects and technical data

Features

  • PDF-Comparison 
  • Advanced defect classification 
  • Multiple ejection parameters per quality level possible
  • Advanced LED and color camera technology 
  • Integrated data mining and reporting tools for the most efficient process and quality decisions 
  • Inline color monitoring for Delta E or LAB 
  • Inline edge control for permanent inspection of position accuracy 
  • Automatic repetition of Color Measurement bars 
  • Reporting on the machine speed
  • Machine speed reporting 
  • Maintenance reporting 

Typical defects

  • Scratches
  • Slugs
  • Splashes 
  • Streaks 
  • Register defects 
  • Missing print 
  • Color deviations 
  • Toning & smearing
  • Doubling
  • Contamination of the weld seams

Technical data

  • Max. resolution 85µm
  • Max. Speed 10,000 sheets / h
  • Max. Format 1350 x 2000 mm (WxH)
  • Required installation space 400 x 400 x 1400 mm (WxHxD)
  • Can be used before and after drying
  • Digital I/O interface for e.g. ejection, feeder stop, horn, traffic light, etc.
  • Remote maintenance access and reporting via TCP/IP

Arkin increased process efficiency for flawlessly decorated metal packaging

Arkin, a Turkish manufacturer of metal packaging used for oil cans, food and non-food applications, increases print quality with a 100% inline inspection solution. The high speed of the printing press and the increasing number of colour applications made it difficult for ARKIN employees to monitor production and detect defects. ISRA VISION offered the perfect solution for this with DecoSTAR: the inspection system guarantees 100% inline inspection of up to 10,000 sheets per hour.
 

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Flawless coating of metal sheets thanks to automatic quality control

Coating and metal sheets

When coating metal sheets, reproductions due to unsaleable materials, low throughput and high material waste lead to an increase in production costs. For this reason, only perfectly coated sheets may be processed in the printing press. Our CoatSTAR inline inspection system recognises faulty sheets as early as the raw material preparation stage and ensures that they are removed from production. Throughout the entire production process, CoatSTAR automatically records data on coating quality, dimensional accuracy and the quality of the weld seams. This data can then be used either for internal process analyses or as proof of quality for the customer. CoatSTAR fulfils the highest quality standards and is suitable for any machine thanks to its modularity.

Benefits

100% inline inspection for every single sheet at the highest coating machine speed

Easy to operate. The intuitive setup procedure for new jobs or use of existing job files

Detection of defective sheets at the earliest possible stage of your metal decoration process

Coating inspection assures the best conditions for a later print run

Inline control of the uniformity of the coating surface

Checking the dimensional accuracy of each sheet

Modern LED and line scan camera technology

Features, typical defects and technical data

Features

  • Continuous monitoring of paint quality, dimensional accuracy and weld seams at a glance
  • Multiple ejection parameters per quality level possible
  • Defect marking signal: for mechanical marking of incorrectly coated sheets
  • Automatic masking function
  • Adjustable area sensitivity: individual setting option
  • Extended compensation of sheet movements
  • Scroll sheet detection

Typical defects

  • Scratches 
  • Lacquer splashes
  • Holes
  • Soot particles
  • Inclusions
  • Lack of coating
  • Contamination of the weld seams

Technical Data

  • Max. resolution 170µm
  • Max. speed 12,000 sheets / h
  • Max. format 1350 x 2000 mm (WxH)
  • Required installation space 200 x 200 x 1400 mm (WxHxD)
  • Usable before and after drying
  • Digital I/O interface for e.g. ejection, feeder stop, horn, traffic light, etc.
  • Remote maintenance access and reporting via TCP/I

Raising quality and productivity for coated and printed metal sheets

Cinbal - one of the largest manufacturers in South America - responds to the high cost pressure in the production of metal packaging with 100% inline inspection. The producer was faced with the difficulty that defects were not only occurring during the decoration process when printing, but also beforehand when coating the sheets. The CoatSTAR and DecoSTAR inline inspection systems offered a solution.  
 

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Production analytics - Data-driven production 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.

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.

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. 

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

Web-based solution, no client software installation required

Department oriented dashboards, customer specific adaptations are possible

Live insights from real time data

Threshold monitoring and alerting

Open to integrate relevant third-party data and export data to the customer's systems

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