Top quality requires highly accurate control. Even the smallest printing errors can result in considerable costs and harm the print shop's image. Packaging printing for pharmaceutical products and branded goods, label printing and the printing of security documents in particular require stable and reliable production of the highest quality standards.
Designed for the Speedmaster® XL 106, Speedmaster® CX 102 and Speedmaster® XL 75 series, the Prinect Inspection Control inline sheet inspection system seamlessly controls and documents the entire print run. The automated early warning system ensures the maximum possible security in the printing process - at any speed. Prinect Inspection Control identifies and reports print errors before they can generate any follow-up costs. This puts an end to costly manual quality assurance measures or expensive reprinting of the whole run due to minor printing errors.
In order to fulfill different customer requirements, Heidelberg offers two inspection systems:
Particularly in packaging and label printing, guaranteeing the quality of a printed product is not just a matter of correct inking. Printing errors need to be identified at an early stage in order to ensure there are no complaints.
Prinect Inspection Control 2 delivers top performance when it comes to sheet inspection. Two high-resolution color cameras in the coating unit of the press fully check each sheet for material defects, hickeys, ink splashes, scumming and so on to prevent follow-up costs. The blower air-assisted optimized sheet guidance permits a comprehensive inspection right up to the trailing sheet edge.
The new Operating Assistant, in conjunction with the Prinect workflow, enables a rapid, straightforward setup process on the Wallscreen XL. Hardly any of the settings are manual.
Shortest makeready times
Prinect Inspection Control 2 with PDF comparison offers the possibility to compare the first OK sheet with the approved PDF data from prepress in an automatic and objective way before production start.
All deviations are displayed on the wallscreen and must be evaluated by the printer. The saved job-related inspection report documents this process and the approval to print.
The benefit: Defects caused by wrong or defective printing plates can reliably be identified before production start. These can then be corrected before they create serious problems.
Once the image area to be inspected has been defined in setup mode, the digital reference sheet is automatically created and stored by Prinect Inspection Control when OK sheet production begins. This process takes place inline and is extremely fast. Prinect Inspection Control compares each print sheet with this reference sheet and alerts the printer as soon as print errors have been detected. If the system identifies a flaw, a tab inserter integrated into the delivery automatically marks the beginning and the end of the defective sheet.
The incorporation of two color cameras together with the illumination unit directly into the coating unit is not only an impressive technical achievement but also highly efficient. The inline inspection system is fully integrated into the coating unit and features an exceptionally low-vibration design. This ensures the best conditions for a consistently high standard of inspection. The fact that both cameras are fitted very close to the printing nip allows constant control of all moving print sheets right up to the rear sheet edge at full production speed and with highly efficient inspection results. The blast-air-supported sheet travel keeps the sheet reliably under control - even at high speed.
In order to ensure that even the smallest print errors, such as hickeys, missing print, streaks and scratches, are reliably and quickly detected, Prinect Inspection Control works with two high-resolution cameras. This makes the system four times more sensitive than other systems (twice as sensitive for sheet length and sheet width respectively). The resulting resolution of 0.25 × 0.25 millimeter (RGB system) respectively 0.18 mm x 0.21 mm (PDF system) divides a 1,050 × 740 millimeter format sheet into incredible 12 respectively 20 million pixels - and this at maximum printing speed! The PDF comparison (PDF system) even doubles the resolution to ensure that even the "icing on the cake" can be detected.
Prinect Inspection Control continuously supplies the results of its inspections to the Prinect Press Center press control station. The printer views the evaluations on the large wallscreen. The cutting-edge image processing software displays the errors on the sheet clearly and on a large scale, ensuring ideal conditions for rapid error analysis and assessment. All other operating functions can also be controlled via the wallscreen of the Prinect Press Center XL. These include setting multiple inspection areas, the overview and zoom function and the error history using thumbnails. The option of choosing between five tolerance levels means inspection quality can be perfectly geared to different customer requirements.
The integrated reporting function offers seamless documentation of the whole run. An authoritative proof of quality is generated for every inspection. This can be archived in the network and printed out at any time from any network PC. This means complaints can be traced even years later. The quality of the supplier's printing stock can also be assessed and any complaint-related costs justified.
As an option, data from prepress can be used to preset inspection areas and tolerance levels of the system. In using the die cutting contour, for instance, only print errors located in the blanks are detected. This limits the warnings to customer-relevant print flaws and tabs them only in the delivery pile. In addition, this eases the setup process and cuts make-ready time significantly.
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