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monitor register behavior – making the costly and time-consuming process of stopping the printing press for fine-tuning outdated.
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.
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*).
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.
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.
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.
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.
생산 시스템의 효율적이고 미래 지향적인 운영을 위해 우수한 자격을 갖춘 서비스팀이 모든 문제에 대해 전 세계적으로 고객을 지원합니다. 연중무휴 24시간 신속하고 안정적으로 시스템의 구현, 유지보수 및 서비스는 물론 분석 및 최적화를 제공합니다.
또한 유능한 트레이너를 통해 시스템 운영자, 제품 엔지니어 및 품질 관리자가 진정한 검사 전문가가 될 수 있도록 직원들에게 항상 최신 지식을 제공하는 방법을 알아보시려면 ISRA 아카데미를 방문하세요.