Today, label converters have a multitude of high-tech options to ensure that they catch every print defect, every time. What follows is an overview of some of the leading inspection systems currently available in the market.

AB Graphic International
The fleyeVision 100% camera system from AB Graphic International is a fully modular system for all inspection needs. “Add value to your business while being confident that each label you send out is verified by a 100% camera inspection system,” the company says. The system uses line scan technology, going from 1k to 8k resolution cameras to detect print errors such as scratches, text irregularities, ink blobs and registration shifts, as well as color variations. The fleyeVision system is also capable of inspecting reflective foils and holograms. The system is capable of being mounted on press, or on finishing equipment, and works by identifying an error and then presenting the error to the operator depending on the application.

The fully modular fleyeVision system from AB Graphic ensures that the customers exact requirements are met. Available options include full color inspection, bar code inspection, OCR inspection, PDF comparison modules, pharmaceutical inspection modules and even Braille inspection.

Specifically designed for booklet labels,  AB Graphic offers the Omega 3010. Based on its experience in booklet inspection and the inspection of high security products, the Omega 3010 can rewind booklet labels in 330 and 410 mm web widths. Driven by a new intelligent menu system and a new accumulator, the Omega 3010 can inspect printface control as standard while offering a wide range of inspection options including, bar code inspection, OCR and Braille. With the Omega 3010, each defect is inspected and then re-inspected to ensure a 100% error-free web suitable for the stringent standards of the demanding pharmaceutical industry or other high security applications.
www.abgint.com

Advanced Vision Technology (AVT)
Advanced vision Technology (AVT) is a global provider of print process control, quality assurance, and press control for the packaging, labels, and commercial print industries. More than 7,000 AVT systems are installed at customer sites worldwide.

AVT’s ZeroSet was designed to provide support to the digital print environment, meaning that even very short runs can be automatically inspected, leading to improvements in quality control. In addition, printing press operators utilizing ZeroSet do not need to define system data nor print information during the printing process. This lack of user intervention greatly diminishes the likelihood of mistakes.

ZeroSet is enabled by a link between the prepress workflow with the AVT inspection systems. The prepress operator identifies the critical areas in the job to be checked. The Automation Engine will then submit all setup related parameters to the AVT inspection system using the JDF fil, eliminating the need for printing press operators to set the system on-press.

AVT’s ZeroSet also offers uniformity: an automation-triggered setup enables all users to start from the exact same quality specifications. It also easily addresses job audits. By combining ZeroSet and JobRef, the user can compare the print to a proof PDF inline. Users can print 10 or more jobs one after the other. AVT will automatically compare the print to the proof PDF, compose a report and send it to the customer MIS to be reviewed on any user terminal in the site.

This product is supported by AVT’s leading inspection systems, Helios II for narrow web labels and Apollo II for flexible packaging. According to AVT, both systems offer a combination of state-of-the art vision technologies to facilitate the highest level of inline process control and quality assurance, and identifies defects as soon as they occur – thereby lowering waste, improving quality and providing 100% quality assurance.

Helios and Apollo include Line Scan CCD camera module qualities for defect detection, 100% quality assurance and additional processes. Helios and Apollo can deal with a range of faults such as color variations, streaks, low contrast defects as hazing or scumming, misregistration, spots, splashes and more. The flexible, integrated database tracks errors for downstream removal, and records them for further analysis.

“The ZeroSet inspection system delivers two very valuable benefits: it makes smaller and digital runs more cost-efficient to thoroughly inspect, and significantly reduces the risk of human error,” says Amir Sheinman, vice president of corporate marketing for AVT. 
www.avt-inc.com

Erhardt + Leimer
Erhardt + Leimer markets the Nyscan Web:Inspector2 100% print inspection system.

“The Nyscan system uses only line scan camera technology, allowing for the entire web to be inspected at all times,” explains Todd Guzzardo, vice president of sales and operations. “One of Web:Inspector’s key features is its lighting system, TubeLight. Using high intensity LED strips and a tube-shaped diffusion chamber, the web is evenly lit by fully homogenized lighting. This diffusion allows Web:Inspector to reliably inspect on difficult substrates such as foils, metalized papers, even holograms – all without the need for special modules. Also, our customers are really excited about our new user interface and how intuitive it is to operate.” 

Web:Inspector:2 can integrate with the Nyscan Image:Inspector, a PDF comparison tool. By comparing the reference image from Web:Inspector to the customer-approved PDF file from prepress, Image:Inspector finds any differences, ensuring consistency from prepress to press. Once the reference image is approved, all production on the press is monitored and any unacceptable defects are saved in the job’s Roll Map. The Roll Map can then integrate into a slitter/re-winder via Nyscan‘s Roll:Scheduler. Using Roll:Scheduler, a Roll Map can be reviewed, edited, and then used to automatically control a finishing machine.

Erhardt + Leimer also offers a premium web viewing system, Elscan. “The system’s configuration consists of two five-megapixel cameras arranged in a concentric field of view allowing for a full view of the print repeat. Using a digital zoom controlled by the scroll wheel of the mouse, the operator can achieve the maximum magnification without delay,” explains Guzzardo. “Coupled with a motorized traverse, the camera can be placed anywhere across the web at speeds up to 1,500 mm/second to ensure optimal repeat viewing.”

Features such as a position library, delta-E color comparison, and register pre-adjustment are a few of the options available. Modular in design, it can be configured to most any environment.

Erhardt + Leimer has recently introduced the new ELCAM Matrix and Missing Label Detection system (MMLD) to handle all PS label substrate types. With set up times of less than five seconds and no moving parts to adjust, Erhardt + Leimer says this camera-based system is a low cost alternative to the time consuming set-up procedure of conventional sensor arrays, especially those for clear-on-clear missing label inspection.
www.erhardt-leimer.com

Label Vision Systems (LVS)
Label Vision Systems (LVS) provides 100% print quality inspection and in-line process control systems for a wide range of print applications from flexo, litho, narrow and wide web applications to thermal printers and packaging lines. LVS systems are installed in more 40 countries and are utilized in over 40 Fortune 500 companies and over 200 Life Sciences companies.

LVS offers master-to-label comparison, delta-E/color process control, OCR/OCV, sequential/random data validation, read/ISO grade 1D and 2D bar codes and more.  New system offerings include the latest GbE hardware technology: line scan and area scan entry level inspection systems for basic applications like back numbering, single lane ISO grading both 1D and 2D bar codes, web monitoring, package line inspections and more.

The new AutoScan Web Viewer Module allows an operator to simultaneously monitor up to 16 areas of interest on the web without having to manually move between each area of interest, allowing an operator to manually keep track of the printing process while the LVS 7000 is automatically inspecting 100% of the labels for defects.

The PDF Compare Module, powered by LVS partner Global Vision, ensures the approved customer PDF file matches the actual print job. Any differences are automatically detected and flagged to the operator. A detailed inspection report can be generated for quality control records and approvals.

The in-line LVS 7500 system offers 100% print quality inspection and bar code verification capabilities for use with thermal printers, thermal transfer printers, and other slow-speed roll/fan-fold printing applications. The LVS 7500 was designed to provide a cost-effective means to identify defects, avoid liability, reduce re-work, and control waste resulting from labeling or print quality errors. 

Off-line products include the Integra 95XX Series bar code verifiers, which validate the quality and data within 1D and 2D bar code symbology to ISO, ANSI and GS1 standards. The Integra 95XX Series inspects all nine ISO/ANSI parameters for 1D bar codes, plus added features of determining blemishes, opacity and human readable validation. Analysis is color-coded to show exactly where the problem is located within the bar code.

The Integra 95XX Series of verifiers are certified by GS1 US and are 21 CFR Part 11 compliant-ready. Included in the Integra 95XX Series are the Integra 9510 desktop verifier, Integra 9570 handheld verifier and the newest verifier from LVS, the Integra 9580, a portable, handheld verifier. 
www.lvs-inc.com

Lake Image Systems
Discovery is a suite of inspection and data integrity systems that grew out of the transactional document printing and mailing market. Experienced with the demands of traceability and data integrity, Lake Image Systems says migration into the label market has been rapid and is now the company’s strongest growth sector. Discovery’s software, hardware and optical tool sets are optimized for the traceability, management and inspection control of variable data on complex substrates.

Discovery Multiscan is a camera or scanner based platform that can read, grade and verify most code formats including bar code, 2D, QR and OCR, at speeds in excess of 300m/min in either sheet or web form. In addition, print quality, registration and color variation tools can simultaneously provide more traditional inspection functionality.

Discovery Multiscan can operate with a wide range of camera and scanner technologies, including line scan with resolutions up to 12,000 pixels across a web, giving sufficient resolution for even the smallest code, or print defect, without the complexities of multi-camera installations. A recent development now incorporates the latest Contact Image Sensor technology, giving true 600 dpi resolution, in full color, for web and sheet widths up to 926mm.

Discovery Roll Review and Roll Sequence tools enable the tracking of faulty labels identified during the print stage, through the rewind and slitter process for removal or correction.

While online press level integrity and inspection is managed by the Discovery Multiscan installation, Discovery Enterprise is the facility-wide product for managing variable data print runs across multiple machines and processes simultaneously. The SQL server platform can provide real time duplicate detection, integrity verification and reporting for multiple jobs operating across multiple processes. Taking the data from each Discovery Multiscan installation on site, Discovery Enterprise provides real time job data to individual label level. Jobs can remain resident for long periods of time, typically required for shipping and tracking label production, therefore preventing duplicates of any one label.

Real time replication and database archiving provide disaster recovery functionality, while the browser-based GUI can provide web-based access to approved system operators.

“Demand for these short run, highly secure labels is a rapidly growing sector in the market,” says Martin Keats, managing director at Lake Image Systems. “For several years, the focus has been on the printing technology to meet the efficiency and quality demands. Now that this is proven and established, the inspection requirement is becoming the focus. While print quality remains an important factor, the integrity of the label data is critical. The penalties for duplicate or untraceable labels are significant, and therefore a new approach to inspection is required that combines all inspection and data integrity disciplines across multiple print processes simultaneously. We feel we have accomplished this within our Discovery development strategy.”
www.lakeimage.com

PC Industries
PC Industries designs and manufactures vision inspection, quality control, and process control systems for the pharmaceutical, packaging, labeling, and converting industries.  The company offers several types of inspection systems designed to fit a variety of print inspection needs.

The Guardian PQV offers the widest range of inspection capabilities of all PC Industries’ products. Capabilities include 100% inspection, sequential data verification, OCR/OCV, ANSI/ISO bar code grading and verification, and defect roll mapping. The PQV can be customized to fit demanding applications, including currency inspection where UV, IR, transmissive, and regular print features, as well as serial numbers, must be inspected and logged with the utmost accuracy. The Guardian PQV is also designed to provide security, creating an audit trail of defect history and operator action, so converters can guarantee product accuracy to customers.

Available features include bar code decoding, verification and ANSI/ISO grading; optical character recognition and optical character verification; sequential number verification; dimensional gauging; defect roll map (which includes the location and image of each defect on a roll); and Braille inspection.

The Guardian OLP is designed for prepress proofing and pressroom quality control. In prepress, samples, stepped files, and proofs are verified against customer-approved artwork. In the pressroom, the Guardian OLP verifies the first article of inspection and performs make-ready and end-of-roll verification.

For prepress applications, the Guardian OLP compares production files to a customer approved PDF, ensuring that no images or text are lost or changed while preparing files for press. The system can also be used to provide an extra level of revision control, helping to assure that the correct version of the product is sent to press. It is capable of bar code decoding and inspection, Braille inspection, variable data check and much more.

Also available is the Guardian PQV Mini, which the company describes as an economical, modular vision inspection system. It is a 100% customizable system. Additional modules can be purchased as needed, including 100% inspection, defect roll map, OCR/OCV with sequential check, bar code decoding with sequential check, ANSI/ISO bar code grading and FDA 21 Part 11 compliance. The system has a small footprint and can be installed on any press, slitter/rewinder, thermal printer, converting or packaging line.

PC Industries also offers the Graphic-Vision GV500 Series Digital Web Viewer, which has long-lasting LED lighting, high-resolution color cameras, and an LCD monitor. The GV500 Series web viewers use high-resolution cameras to capture and display images from the web to identify press-defects, such as misregistration and color variation. Bar code decoding is included as a standard feature on all GV500 models.

The systems are available in four configurations. The GV510 offers a manually adjustable traverse and a remote control for camera settings. The GV520 adds a motorized traverse with automatic lateral scanning, allowing the operator to inspect across the entire web, or quickly move to different regions of interest. The GV530 offers programmed- and combo-positioning. This allows inspection at the regions of interest to be automatically sequenced, with the time at each position adjustable.

The GV530/Spectro is the newest member to the Graphic-Vision family. It provides all the functionality of the GV530 with programmable and combination positioning, and now also includes a full spectrophotometer for color measurement in 31 spectral bands and real-time reporting.
www.pcindustries.com

Prati
Prati supplies machines for self-adhesive label finishing, covering customization, inspection, diecutting, matrix removal, rewinding, slitting and overprinting. The product range includes the Jupiter and Saturn/Sun inspection tables, the modular and adjustable VEGAplus platforms, and the Pharmacheck finishing system, which is tailored specially to the needs of the demanding pharmaceutical industry.

The Pharmacheck is a modular system that addresses the strict standards of the pharmaceutical industry. It integrates an innovative and efficient system where paper moves only in the forward direction. Servo technology is employed for maximum accuracy in all the machine’s working phases. Accuracy in web tension, slitting and web alignment is maintained. The absence of a buffer permits a clean process with no stress for the labels, no misalignment and no tension issues; 100 percent label quality inspection is ensured with the integration of camera inspection systems. All errors are tracked and quickly positioned for repair, saving time and increasing productivity.

The short web path allows minimal touching of the paper on the idler rollers, thus securing clean and easy processing even of booklet labels and difficult jobs. The video controlled slitting function ensures absolute and continuous accuracy in row slitting.

“Prati machines are extremely robust and reliable, with low maintenance requirements and guarantee a fast return on investment,” affirms Chiara Prati, sales manager at Prati. “They are very modular and can be configured to meet customer-specific requirements. We are committed to offering label printers the opportunities to diversify, expand or improve their production range with Prati quality products and services,” Prati concludes.
www.praticompany.com

Rotoflex
Rotoflex machine designs have been on the market for more than 40 years and have more than 7,000 installations globally. As a part of Mark Andy Inc., Rotoflex has access to extended engineering and technical expertise to enable more integrated and seamless workflows. The company says it is on a mission to be a “Total Solutions Partner” for finishing equipment including inspection, slitting, rewinding and diecutting machines.

Rotoflex VSI and VLI models are the leading machines offered by Rotoflex and sold all over the world. Both models are fully servo-driven and provide high-speed, inspection rewind capabilities.

Unique to the Rotoflex product line, the URC 2.0 control system is designed to deliver accuracy with an intuitive interface that allows operators to monitor all functions and identify faults from a single screen. The high-security counter with built-in missing label detection gives maximum label count accuracy, and label length count measurements are precise with an error-free shaft encoder interface.
 
Rotoflex equipment is designed to easily integrate with any third-party peripherals and vision systems. Its modular design allows for future updates as converter requirements change. Integration of URC 2.0 on multiple machines on the production floor allows operators to transfer from one machine to another without re-learning the intricacies of a new control system.

Additionally, the Rotoflex Report Management System has been developed to gather productivity data from Rotoflex machines via a wireless router, and then provide it to stakeholders in real-time. This allows production managers to receive and audit data, then isolate and resolve any issues or discover productivity improvements.

Arpeco was purchased by Mark Andy in 2010. The acquisition brought to the company’s offering the Tracker line of inspection machinery. Known for its popular horizontal machine design, the Tracker has been retained under the Rotoflex brand.

To support its goal of being a “Total Solutions Partner,” Rotoflex says it is committed to delivering high quality, innovative products that respond to industry demands. Integrated into new machines, Rotoflex rolled out a new, fully servo-driven platform at Labelexpo Americas. Throughout the event, Rotoflex demonstrated the new capabilities, running the machinery at 2,000 feet per minute.  The new servo design  and integration of eDrive web management tools aim to improve production capability, running speeds and delivery of consistent and high quality rolls. Additionally, Rotoflex servo implementation, combined with the exclusive URC 2.0 operating system, provides improved web and material stability and control.  
www.rotoflex.com