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Zero defect production: maximum reliability of productivity and quality for packaging and commercial printers with new inline inspection system from Heidelberg

04/25/2017

  • Prinect Inspection Control 2 ensures precise inspection with high-resolution color cameras and avoids paper waste and complaints
  • Total ease of operation for fast setup
  • Complete integration into the coating unit for optimal protection and ease of accessibility
  • High level of automation through integration into the workflow
  • Software options for flexible function enhancement
  • First users report improved quality and cost savings through inline quality monitoring

The print media industry frequently faces demands for high quality in combination with ever shorter throughput times, complex products, or just-in-time production. Any company wishing to be successful here needs a digitized and automated control systems that goes well beyond manual quality assurance methods, since even the smallest printing defects can cause significant costs and damage a print shop’s image.

Zero defect production and timely detection of printing defects are therefore becoming more and more important for industrial packaging, label, and premium commercial print shops. With the new generation of the inline inspection system Prinect Inspection Control 2 from Heidelberger Druckmaschinen AG (Heidelberg), print shops can now realize maximum reliability of productivity and quality in their day-to-day production. Prinect Inspection Control 2 thus ensures zero defect production, an aspect which Heidelberg will be addressing both at the Interpack trade fair in Düsseldorf and at the subsequent Packaging Days in Wiesloch-Walldorf. Both events will be taking place under the motto “Smart Print Shop – Zero Defect Packaging” (Press Release: Heidelberg and Gallus at Interpack).

Prinect Inspection Control 2 is now available for the Speedmaster XL 75, CX 102, XL 106, XL 145, and XL 162 model ranges with coating unit.

High automation through integration in the workflow

The Prinect Inspection Control 2 concept is based on a completely new hardware and software platform. It uses two high-resolution color cameras that inspect the full sheet at high speed without any loss of quality and point out any defects to the operator in real time.

Prinect Inspection Control 2 is fully integrated into the coating unit and thus offers ultimate protection against dust and splash waster. All electronic components are temperature-controlled via the connection to the inking unit temperature control for the best possible inspection results and a long service life.

Prinect Inspection Control 2 can be extended with two software options depending on additional quality and safety requirements. For example, the setup time can be shortened by automatically transferring inspection areas from the prepress stage (“Preset Inspect” option) or the system can be equipped with a PDF inspection function (“PDF Verification” option). With the “PDF Verification” option, a comparison with the prepress PDF is automatically performed during the setup process. This enables defects to be detected at an early stage and follow-up costs to be avoided.

Prinect Inspection Control 2 automatically generates a digital reference sheet once production of good sheets begins, and every sheet is checked inline. The smallest defects like hickeys, missing print, streaks, smudging, and scumming are immediately detected and shown on the Wallscreen XL. The start and end of defective sheets are automatically marked by the tape inserter integrated into the delivery for further production reliability.

Complete integration into the workflow permits automatic assignment of all necessary job data, inspection areas, or the digital reference sheet. The operator can concentrate fully on the press, and is not preoccupied by time-consuming setup processes. After the job is completed, quality reports are automatically generated on a job-specific basis in the Prinect Analyze Point for tracking purposes.

Easy operation combined with the highest inspection quality

Prinect Inspection Control 2 features automated and self-explanatory operation via Wallscreen XL. For different quality requirements, the printer can choose between five inspection tolerances that can be automatically loaded from the prepress stage. Printing defects that occur are shown on the Wallscreen sorted by their size and assigned to the position on the sheet so that the operator can immediately detect the defect - all in real time. The optimized sheet guide together with the LED illumination and continuous paper white measurement guarantees first-class inspection results with a minimum of maintenance.

First-time users report better quality and saved costs by quality control in the printing press

As one of the first users, the Aug. Heinrigs printing company belonging to the RLC Packaging Group is using the new Prinect Inspection Control 2 on a Speedmaster XL 106-8 + LYYL. At its Aachen location, the company mainly produces premium packaging for confectionery manufacturers and cosmetics. "The Prinect Inspection Control 2 offers us additional security in the production of high-quality packaging", confirms the Print Process Manager Daniel Blatt. "By constantly monitoring the pressure, errors are detected immediately and the operator can react directly. Our experience with the system is very positive, because even the smallest errors are detected, which usually remain undetected. This, of course, reduces the risk of waste and complaints.

Novaprint in Oldenburg, a member of the Bagel packaging group, is also one of Prinect Inspection Control 2's first printers. The company produces high-quality security labels, labels for the beverage and food industry, and is a specialist in promotional packaging. "Thanks to the automated PDF adjustment, we can carry out the adjustment with the precursor data while setting up, saving us a lot of time on the Speedmaster CX 102-8 + L," says production manager Marco Berg. "This is a great advantage, particularly in the case of printing forks with many similar labels, which considerably reduces the burden on the printer. For the inspection, we also use the presetting data from the prepress. This accelerates the set-up process and focuses the inspection within the punch contour on reliable errors in the use. "According to Berg, the printers work with the system because it is highly automated and easy to use. As a result, Inspection Control 2 is used for PDF inspection and print control during every job.

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Hilde Weisser
Public Relations Officer, Trade Press Tel.: +49 (0)6221 92 50 66
Fax.: +49 (0)6221 92 99 50 66

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