LEMU Group GTU Turret Rewinders Includes ADD Hi Speed Quailty Control Integration

At Lemugroup we continue to innovate in order to offer the industry solutions that guarantee correct production efficiency. The most recent solution achieved by the collaboration between LemuGroup and BST is the integration of the Tubscan system in LemuGroup’s GTU rewinders. This solution provides 100% full inspection and quality control roll mapping.

The GTU rewinder can operate as a stand-alone module or be integrated with LemuGroup printing and die-cutting modules or any other OEM press or converting line including hybrid presses.

We have achieved an important milestone by integrating into the GTU rewinder the Tubscan 100% inspection system, which allows us to identify printing errors, matrix waste and defects thicker than 5 mm.

The process consists of a first phase where the operator enters the label design into the inspection system and registers this as the label quality standard. From here, the system has a photo to compare the rest of the labels being run with.

Once the standard is defined, the Tubscan performs an exhaustive comparison, generating a complete mapping of the errors found. This information is sent in real time to the GTU Turret Rewinder, which records the data and prints it on the roll closure labels.

This data includes:

Whether the roll has errors.
Number and type of errors detected.
A QR with the BST Roll Map, detailing the location and description of each error.
Variable data depending on the customer’s needs

With this data, the operator identifies the error, adjusts the machine and removes the roll from the production process.

This complete line is very useful for all those sectors that need an exhaustive quality control such as Pharma and Nutraceutical labels, as well as RFID and Prime Labels.

THE IMPORTANCE OF 100% QUALITY

With the integration of the Tubscan 100% full inspection system on the GTU rewinder, converters have a production process monitored in real time with the possibility to correct small deviations, reducing the number of incorrect rolls. Detailed reports allow and enable constant improvements and ensure processes producing a 100% quality product removing the editing or need for a QC second pass.

The process can be upgrade by automating the end-of-line with the UltraCompact. The UltraCompact would take care of removing those defective rolls from the production process.