Professionals. For. ipq_solutions. ipq. Increasing Productivity and Quality Solutions

Transcription

1 For video_sta eb r w Professionals. _check 2. in ipq o_check inc 0 ipq_solutions tw Increasing Productivity and Quality Solutions wo r k _ fl o w _ Web viewing _ 100 % print inspection _ Spectral on-press color measurement _ Workflow solutions

2 ipq_solutions System overview web viewing spectral color measurement multitouch Screen 100% print inspection or 100% cold seal inspection back light Printing quality efficiently Your customers expect perfection in quality. Your benefits At the same time, competitive pressure _ Convince by keeping quality diminishes your margins. This is where ipq_solutions begin: it improves your productivity and helps compensate your promises reliable _ Increase profit with new and existing customers _ Achieve a drastic reduction of waste by decreasing margins. optimized processes and fast reactions As a modular system, our ipq_solutions are unique to the market. We design a solution tailored specifically requirements. All to your modules _ Investment is future-proof with a solution which grows with your demands individual match up perfectly and all of them are operated by a central user interface. More than 600 customers trust our ipq_solution since years. Choose the new benchmark in optical quality measurement for yourself! 2 ipq_solutions ipq

3 Content Web viewing With its excellent image quality and field-proven simple operating concept, the modular webvideo_star is a professional tool for optical quality control Page 4 webvideo_star _ Safe decisions based on excellent image quality _Less waste thanks to fast reactions _ Modularity goes easy on your budget and makes your investment future-proof 100% print inspection Thanks to latest state of the art technology and intelligent algorithms of twin_check 2.0, you ensure your quality promises and improve your productivity at the same time. Page 12 twin_check 2.0 _ Reliable identification of defects and fast elimination of causes _ Overview of the whole production s quality prevents overproduction _ Eliminate defects securely and keep your quality promises Spectral on-press color measurement Page 20 With inco_check, you can now shift your color control to be throughout your entire printing productions. This is how you ensure a constant quality level of your products and reduce waste at the same time. inco_check _ On-press color measurement values are directly available for the color kitchen _ Log files serve as proof of quality and as a basis for waste reduction and process improvement _ Less waste during production make-readies Workflow solutions The on-press inspection offers extensive possibilities to influence both your quality and productivity levels. With the work_flow modules, you open up these various possibilities: work_flow _ PDF plate_auditor on press copy check _ waste_indicator precisely provides error signals _ event_logger consistently records defects _ quality_assistant harmonizes quality standards _ rewind_navigator increases packaging efficiency Page 26 Further modular options Additional module offerings complete your individual ipq_solution. This is how a solution tailored to your specific demands is created. And you invest only in the system you really need today Modules _ Comparative inline color measurement _icm _ Sample inspection _sis _ Barcode inspection _bc _ Semi-automatic CI register control regi_touch Page 30 ipq_solutions 3

4 webvideo_star Seeing, what s important webvideo_star 4 webvideo_star

5 Benefits First class digital web viewing Nowadays, many steps of a process can be automated. For an assessment of print quality, the human eye is still essential. webvideo_star is an essential tool for optical quality control and an essential component of eltromat s ipq_solutions. The modular configurable system provides excellent image quality. That is how you ensure making the right decisions. In doing so, the intuitive operating concept allows fast reactions. Thus, your operators will concentrate on their most important tasks. Many more functions and options turn the web viewing system into a multi-purpose tool for your quality control. We have further modularized the web viewing platform which has been already field-proven for many years. Now, the webvideo_star is even more adaptable to your individual demands. Your benefits _ Safe decisions based on excellent image quality _ Fast reactions reduce waste _ Less investment thanks to modularity _ Subsequent expendability makes your investment future-proof webvideo_star 5

6 System features System features Different camera options for varied demands webvideo_star is offered with either 1-chip or 3-chip digital cameras. Both of them are reliably providing brilliant image information. Different optical zoom variations make it possible to adapt the field of view to your demands without any image quality loss. A motorized traverse bar precisely positions the camera across the web. A high performance flash a real all-rounder Thanks to an optimized housing, the integrated high performance flash illuminates the respective printing area evenly. It is suitable for all current manufactured materials. Remote maintenance module for fast help With the integrated option for remote maintenance, the system can be diagnosed easily and quickly by remote service engineers. Modern user interface for a simple operation The revolutionized user interface is not only convincing by its fresh and intuitive design. The modern 16:9 multi-touch-monitor enables touch gestures well known from smartphone or tablet PC, e. g. to zoom or swipe. Thereby, operators can centrally control all functions even more quickly and concentrate on his main tasks. (1) Camera and picture menu: direct access to main operating elements like camera option and settings 2 3 (2) Live image (3) Pull down-menu to access the position memory 1 4 (4) Print format preview makes the control of the field of view easier 6 webvideo_star

7 Functions Split screen for a fast quality control. In the position memory, all camera positions are clearly arranged. Standard functions of the basic model Even the basic model includes a multitude of tried and tested functions: Brilliant image reproduction supports your decisions On the non-glare 23 16:9 - operator monitor, the live image is displayed brilliantly and with high color fidelity. Thus, an optimal live print evaluation is possible at all times. Print format preview Control center and orientation guide For a quick overview and orientation, the camera scans the complete print format and displays it if needed. This is how the operators can select the desired camera position. This process is repeatable exactly at any time. Split screen comparison for more certainty With the split-screen function, your operators see the current live images and simultaneously either a saved reference print (good sample) or a live image of a second camera. The visual comparison between the print image and the reference print increases the reliability of the production process. The images can be displayed horizontally, vertically or as a picture-in-picture display with freely selectable sizes. Scan mode individually decide what the system shows In the scan mode, webvideo_star monitors the entire print format on the basis of automatically defined increments. This offers a comprehensive print check with minimal set up time. In the position memory, you select the exact production monitoring key areas You save individual positions with a particular zoom, iris and flash settings in your system. These positions are displayed as thumbnails in the position memory and can be accessed easily by means of a finger tip. Inspection tasks such as barcode and color measurement can be assigned to any position. Automatic cycle for individually stored positions for maximum comfort In addition, with the stored positions, your operators can easily generate a job-specific automatic cycle. To do so, they adjust the positions and the dwell times of the camera in any random order. Thus, they always have control of the production sequence. Automatic step and repeat cycle use synergies efficiently With the step and repeat function, any saved position can be transferred to any impression of the print format. The system is selecting the increments in the x and y direction automatically, so every impression is monitored. webvideo_star 7

8 Options Modular architecture for your individual demands additional monitor options 23 TFT screen (as additional screen) 23 TFT CCM screen 40 TFT screen housing & remote options operator console joystick control monitor cable extension kit distance > 5m 2nd traversing camera options 1-chip 10x zoom 1-chip 16x zoom 3-chip 16x zoom illumination options shadowless backing plate homogeneous back side flash lacquer flash UV flash embossing flash hologram flash front to back register viewing powerflash basic model webvideo_star processing unit on mounting plate including basic functions 19 multi touch screen camera options 1-chip 10xzoom 1-chip 16xzoom 3-chip 16xzoom motorized traverse bar standard synchronization unit remote maintenance Uninterruptible Power Supply (UPS) extensions screen shot gallery snapshot_gallery barcode inspection _bc sample inspection _sis 100% print inspection twin_check % cold seal inspection twin_check surface comparative color measurement _icm spectral color measurement _inco_check defect data logging event_logger alarm status semi-automatic CI register control regi_touch enhanced image stabilization image_lock eltromat is offering many interesting options for web viewing with webvideo_star with whom you can flexibly extend your basic system to achieve even more functionality and capability. Your requirements decide which elements you install and how you extend your system later on. Added monitors extend your visibility Special color calibrated monitors provide an impressive color reproduction of the live image. Even small details can be recognized from a distance on the 40 monitors. The ergonomic operator console offers more comfort for your operators The processing unit and all further electronic components can be integrated in a special operator console upon request. The ergonomic design extends the comfort for your operators and puts the technology in a safe place at the same time. A joystick improves the operating comfort The joystick is not only an operating alternative, but your operator may control the camera and see the most important points even without direct remote access. Joystick for comfortabe remote control 8 webvideo_star

9 Options An additional matrix camera for doubling your printing security Equip your webvideo_star with a second camera. By getting information from two cameras at the same time, you can react even faster. Or you inspect the backside printing of the running web with the second camera. Furthermore, this option enables the parallel operation of visual inspection and automatic error detection or on-press color measurement. In this way you extend the intensity of your monitoring and gain even more security. Illumination options for special requirements eltromat provides a multitude of special lighting equipment for different requirements. Special flashes for _ cold seal _ lacquers _ fluorescent lacquers _ holograms _ embossing _ register comparison top to bottom in translucent applications _ shadow-free illumination of the print on transparent material (reverse print, front print) without UV flash without lacquer flash with UV flash with lacquer flash without power flash with power flash webvideo_star 9

10 Options snapshot_gallery look at the current production from anywhere in the world Snapshot_gallery enables production support from afar With the snapshot_gallery, your operators can take and save up to 50 pictures per job during production, just by a touch. If needed, you can access the snapshot_gallery via your corporate network and thus support the production wherever you are worldwide. Barcode verification _bc ensures constant legibility The barcode module _bc is detecting even minor deviations which may cause reading problems later on. It inspects all common 1D and 2D codes. This guarantees the highest possible level of reliability for packaging and label printing. [read more on page 33] Sampling inspection _sis entrance to automatic print inspection Compared to a visual quality control, the sampling inspection module _sis offers significantly more objectivity and reliability. Even if the operator leaves the workstation, you don t miss any quality relevant changes. [read more on page 32] 100 % print inspection twin_check 2.0 uncompromising assurance of quality To meet the highest quality standards, webvideo_star can easily be upgraded to a 100 % inspection system. This improves customer satisfaction and productivity. [read more on page 12] Comparative color measurement with _icm or spectral color measurement with inco_check With eltromat s ipq_solutions, you can choose between comparative and spectral color measurement. The comparative color measurement, _icm module detects color deviations compared to the standard color values you defined at production start. The measuring points can be selected easily. With inco_check you measure the absolute L*a*b*C*H* color values. It is combining the advantages of the on-press and the spectral color measurement so you have high productivity with high precision. Your customer s requirements decide which color measurement method is suitable. [read more about _icm on page 31] [read more about inco_check on page 20] regi_touch semi-automatic CI register control without marks (register presetting) When the press is down, the operator assigns and corrects the register at a touch screen with no additional register marks required. As soon as the machine starts, regi_touch fully automatically adjusts the register which reduces set-up waste drastically. [read more on page 34] Additional trigger sensor (PPS) increases image stability Changes in the web tension may affect the image stability in a negative way. With the specifically developed trigger sensor you are in control of that. webvideo_star is assisting you during set-up with a stable image. 10 webvideo_star

11 Technical data Technical data Area of application Print methods Material System performance Max. web speed Max. web width Ambient temperature Relative air moisture Camera Type Objektive Number Resolution Max. image resolution Traverse bar Illumination unit Type User interface Type Resolution Signal input Gravure, flexo printing, reel fed offset printing, digital printing, screen printing, converting Paper, plastic sheet, aluminum (transparent, translucent, opaque, reflective) m/min (3,930 ft/min) mm (110 inch), wider web upon request 0-40 C ( F) (higher temperatures possible with climate control unit) 10-90% (not condensed) 1-chip or 3-chip 10x or 16x zoom 1-2 (depends on application) 1280 x 1024 pixel oder 3x 1280 x 1024 pixel 0,012 mm/pixel ( inch/pixel) motorized, speed up to 250 mm/s (490 ft/min) main illumination, back side illumination*, lacquer flash*, UV flash*, embossing flash*, hologram flash*, powerflash for front to back register viewing* 23 TFT multi-touch screen 1920 x 1080 pixel DVI Supply voltage Power supply Rated current Fuse protection Inputs Function Power supply Input current Outputs Function Power supply Max. output current 115 / 230V AC / Hz depends on application 6A reel change 24 V DC 7 ma alarm signal (error, warning, ok) 24 V DC 100 ma per output, short-circuit proof * optional webvideo_star 11

12 twin_check 2.0 Finding relevant defects twin_check twin_check 2.0

13 Benefits Print quality management along the process chain 100% defect detection waste reduction defect logging defect verification harmonised quality standards minimized defective goods defect elimination increased efficiency improved process reliability PDF prepress print XML roll protocol V1 XML quality control (optional) XML roll protocol V2 finishing quality assurance twin_check 2.0 event_logger PDF plate_auditor waste_indicator quality_assistant rewind_navigator defect prevention permanent waste reduction Simply better! Return on investment twin_check 2.0 is the second central component of eltromat s ipq_solutions. This tool for the quality management combines uncompromising 100% print quality inspection with first-class web monitoring of the complete print format. Especially the packing printing as well as the decor, wallpaper and label printing are typical areas of applications for twin_check 2.0. twin_check 2.0 can of course also be used for defect detection on rewinders, cross cutters and slitters. Your benefits: _ twin_check 2.0 reliably and quickly detects defects and you can correct the causes immediately _ Prevent complaint by logging your production output and removing waste safely _ twin_check 2.0 provides information about the quality of the entire production which helps to reduce overproduction _ Defect prevention always beats defect elimination. By analyzing the defect logging, error sources can be cut out precisely and permanently _ Optimize your process a real cost advantage Practical example Flexo printing press for printing of flexible packaging Possible cost savings EUR per year. ($ 125,826) (52,768) {39,576) (26,384) (13,192) 0 during set-up during production less overproduction during finishing process reduction of customer claims XML defect database defect analysis process optimization time material other twin_check

14 System features The user interface is independent from the main platform and enables the access to quality statistics even when you are in production. Thus, you can always control your production quality. Split-screen enables the comparison between the live and the reference image and can inspect 2 live image extracts simultaneously. System features 100% web monitoring and you have everything under control High-speed image capture High performance 4K RGB color line chip cameras provide detailed image data the basis for web viewing and print inspection. Thus, twin_check 2.0 offers an impressive performance for web widths up to 2,800 mm (110 inch) and machine speeds up to 1000 m/min (3,280 ft/min). Modern user interface for a simple handling The revolutionized user interface is not only convincing by its fresh and intuitive design. The modern 16:9 multi-touch-monitor enables touch gestures well known from smartphone or tablet PC s, e. g. to zoom or swipe. Thereby, the operator can centrally control all functions even more quickly and concentrate on his main tasks. This is how twin_check 2.0 is ready for the new production in less than 30 sec. You have everything under control due to the live view of the print format Immediately after starting the press, twin_check 2.0 displays the live images of the whole print format on the monitor. This live view is permanently shown even with the inspection mode activated. To see more details, the operator zooms, in high-resolution, by gesture control. Especially during set-up, the sharp colors and crystal clear live images contribute orientation and certainty and ease decisions. An additional matrix camera can be easily controlled in the same way. Convenient video functions reduce your waste easily Do you want to compare the current live images with the saved reference print on the split screen or get different details of the complete print format? Either is possible. Deviations in production can be evaluated safely and reliably. Process reliability will be increased and waste is reduced at the same time. Remote maintenance module for fast help With the integrated option for remote maintenance, the system can be diagnosed easily and quickly by remote service engineers. 14 twin_check 2.0

15 Functions (1) Camera and picture menu: direct access to main operating elements like camera options and settings, (2) Live image, (3) Print format preview, (4) Last defect image. In the menu quality control, alley detected defects can be assessed even afterwards. 100% print inspection for a more efficient printing process Inspection of all materials twin_check 2.0 features a powerful LED light source which perfectly illuminates the print images. Designed especially for the inspection of all common opaque materials, this illumination is providing brilliant pictures of the web. With just one finger-tip, it can be adjusted so that the print image can be inspected safely even on high reflecting materials or holograms. For the inspection of transparent materials further illumination options available. Special algorithms enable the reliable inspection of even very flexible materials such as PE, BOPP, OPP, LDPE etc. Reliable defect detection High-performance image processing algorithms detect defects from a grey scale value tolerance of 3% and an allowable indication of 0,0032 mm 2 ( inch 2 ) even before they cause waste. Flexible sensitivity masks put an end to false alarms Annoying false alarms are a thing of the past. Intuitive masking functions allow the inspection of any print image area with different sensitivities. Critical areas are inspected in a particularly critical manner while insignificant areas can be ignored. Intelligent defect classification supports defect analysis twin_check 2.0 differentiates between process related and sporadic defects, no matter if partial missing print, nip-off edges, anilox roll defects, changes in coloring or nonrecurring splashes. This print defect specific classification supports your operators efficiently regarding defect analysis. Defects occurring sporadically can simply be suppressed, if necessary. Fast decisions thanks to clearly structured defect displays If the production is running without faults, only the live image is displayed. As soon as twin_check 2.0 detects a defect, a correspondent defect image will be shown in front of the live image. The defect section will be marked accordingly in the print format preview. Each relevant defect is clearly documented in the menu quality control with a maximum of three images: the first defect image, the last defect image and the image with the largest defect. Thanks to this clear displays and the easy handling, your operators can make fast and reliable decision before several meters (feet) of waste are produced. twin_check

16 Options Modular architecture for your individual demands additional monitor options 23 TFT screen (as additional screen) 23 TFT CCM screen 40 TFT screen housing & remote options operator console joystick control monitor cable extension kit distance > 5m illumination options backside illumination for transparent materials shadowless backing plate matrix camera options up to 2 matrix cameras webvideo_star barcode inspection _bc sample inspection _sis spectral color measurement inco_check semi-automatic register control _regi_touch twin_check 2.0 basic model processing unit incl. basic functions 23 multi-touch screen 1-3 line scan cameras main LED illumination unit syncronization unit remote maintenance module system cabinet uninterruptible power supply (UPS) extensions separated print format comparative color measurement _icm screenshot gallery snapshot_gallery defect logging in a protocol event_logger alarmstatus light reverse side surface inspection twin_check surface workflow solutions comparison PDF and printingplate PDF plate_auditor defect signal output waste_indicator defect protocol verification quality_assistant rewinder control by defect protocol rewind_navigator Many options complete the scope of features possible for twin_check 2.0. Your requirements determine your system s configuration and when and how you extend your system. Illumination options for transparent material A shadowless backing plate considerably improves inspection results for transparent material. A special background illumination unit guarantees perfect results. Added monitors extend your visibility Special color calibrated monitors provide an impressive color reproduction of the live image. Even small details can be recognized from a distance on the 40 monitors. Matrix camera on a motorized traverse bar for additional functions To monitor the web on dot levels, one or two webvideo_star matrix cameras with up to 16x optical zoom can be integrated into the twin_check 2.0. [read more on page 4] Furthermore, this option enables the integration of the following modules _ Barcode verification _bc ensures constant legibility of common 1D and 2D codes [read more on page 20] _ regi_touch semi-automatic CI register control without marks [read more on page 34] Comparative color measurement with _icm or spectral color measurement with inco_check? With eltromat s ipq_solutions, you can choose between comparative or spectral color measurements. The comparative color measurement with the _icm module detects color deviations compared to the standard color values you defined at the production start. The measuring points can be selected easily. With inco_check you measure the absolute L*a*b*C*H* color values. It is combining the advantages of the on-press and the spectral color measurement so you have high productivity with high precision. Your customer s requirements decide which color measurement method is suitable. [read more about _icm on page 31] [read more about inco_check on page 20] Snapshot_gallery enables production support from afar With the snapshot_gallery, your operators can take and save up to 50 pictures per job during production, just by a simple touch. If needed, you can access the snapshot_gallery via your corporate network and thus support the production wherever you are worldwide. A joystick improves the operating comfort The joystick is not only an operating alternative, but your operator may control the camera and see the most important points even without direct remote access. 16 twin_check 2.0

17 Options Additional matrix camera webvideo_star for web monitoring on dot levels. The cold seal inspection shows defects at the application of cold seal; in addition a big live image enables the visual evaluation of the production quality. 100% cold seal inspection everything on the right spot You print packaging and apply cold seal on the back? twin_check surface will help you to reduce waste, over production and improve processes. It is the perfect system for a 100% quality control during production. Minor defect and deviations during cold seal application are immediately detected and displayed. Use twin_check surface depending on your requirements, either as an integrated part of the print image inspection or as an individual system. Your benefits _ Reliable identification of defects and fast elimination of causes reduces waste _ Defect prevention and logging prevent complaints _ Logging analysis support process improvements _ Cold seal and print image inspection from one hand reduces the training effort Suitable for all common materials twin_check surface reliably inspects cold seal on all opaque and metallized foils. 100% web viewing supports the make-ready process The live image of the 100% web viewing enables the operator to visually control the set-up process and supports him with the quality assessment during the running of productions. 100% quality inspection through a consistently defect detection twin_check surface reliably detects all common defects like incomplete or missing cold seal application as well as cold seal on a wrong spot. The operator can react quickly and thus avoids producing unnecessary waste. Defect classification supports defect analysis Furthermore, the system supports the cause analysis by classify the defects automatically. It differentiates between missing cold seal, streaks and scummings. Fast decisions thanks to clearly structured defect displays enables fast action Defects will be displayed directly after they occurred. The operator can react quickly and less waste is produced. Data log The event_logger captures for all detected defects the defect class, running meter as well as the defect image in a data log. In case of a front and back side inspection, the defects of both of them are displayed in a log. Use this complete documentation as proof of quality in front of your customers. Plus, these data support you optimizing your processes. twin_check

18 Options 1 The PDF plate_auditor shows clearly deviations between the acutal print image and the PDF from the pre-press. Activation of the defect signal output based on specific defect classes (1). Workflow solutions for 100% print quality PDF plate_auditor prevents faulty production You are in still the make-ready phase, but the register is already adjusted. Just the right timing for the PDF plate_auditor to compare the printing image with the pre-press PDF. This is how you avoid defect production because of wrong design or language versions or faulty printing plates. waste_indicator delivers accurate defect signals If print defects are detected, the waste_indicator provides a 24 V signal output for the whole web or alternatively for individual lanes. These 24 V signals initiate subsequent processes such as a system to tag waste, a material removal system or you send information to other systems. event_logger provides a data log without gaps The event_logger captures all detected defects related to the lane by recording the defect class, running meter and the defect image together with the corresponding reference image and logs them in a roll log. Thanks to these logs, waste can be eliminated efficiently and thoroughly in the finishing process. The XML format allows an exchange with other applications e.g. for statistic analysis. quality_assistant harmonizes quality standards Not every defect during the printing process automatically causes waste. On the basis of the roll log, the quality_assistant allows you to evaluate the quality of your production quickly and efficiently according to your general quality standards either at a central workplace or directly at the rewinder. rewind_navigator increases your finishing efficiency Based on the roll log, the rewind_navigator triggers your rewinder in a way that the defects to be eliminated are placed precisely at the splice table. Until the next defect the rewinder can continue operating at maximum speed. Thus, precious time is saved. Find more information about our workflow solutions on pages 26 to twin_check 2.0

19 Technical data Technical data Area of application Print methods Material System performance Max. web speed Max. web width Ambient temperature Min. defect size Gravure, Flexo printing, Web fed offset printing, digital printing, screen printing, converting Paper, plastic sheet (PE, BOPP, OPP, LDPE and more; transparent, translucent, opaque, reflective), aluminium m/min (3,280 ft/min) mm (112,2 inch) 0-42 C ( F) 0,0032 mm² ( inch²) at 3% gray scale value tolerance Camera Type RGB color line scan camera Number 1-3 Resolution 3 x 4096 pixel Max. image resolution 0,1 mm/pixel (0.004 inch/pixel) Interface Camera link with 85 MHz Illumination unit Type Form User interface Type Resolution Signal input LED main illumination, reverse side illumination, module for reflective material* 23 TFT multi-touch screen 1920 x 1080 pixel DVI Supply voltage Power supply Rated current Inputs Function Power supply Input current Outputs Function Power supply Max. output current 115 / 230V AC / Hz depends on application reel change 24 V DC 7 ma alarm signal (error, warning, ok) 24 V DC 100 ma per output, short-circuit proof * optional twin_check

20 inco_check reliable color control inco_check 20 inco_check

21 Benefits On-press spectral color measurement for color control colors CxF3 color mixture printing process on-press spectral measurement defect elimination XML PDF color recipe CxF3 Inco_check roll protocol quality report CxF3 reference values CxF3 reference values pre-press process improvement Spectral color measurement optimizes the printing process Especially in package printing as well as in decor and wallpaper printing the subject of color has gained a lot of importance as a decisive quality criteria subject. Brand owners in particular require tight color tolerances. With inco_check the third basic component of eltromat s ipq_solutions you can transfer the spectral color measurement process into your roll fed press, independent of the printing process. This fully automatic and continuous spectral color control provides the basis to come full circle with color control. Additionally, set-up waste is reduced since stopping the press to control the color is not necessary anymore. All measurement results are logged. By analyzing the data log, defect causes within your process can be eliminated systematically and permanently. In short: you optimize your production process. After all, defect prevention always beats defect elimination! Additionally, the protocols also serve as first-class color quality proof for your customers. Your benefits _ You detect color deviations at an early stage. Thus, you may immediately initiate countermeasures _ You can provide your customers with documented proof of quality _ Based on the protocols and workflows you further prevent waste and optimize your process _ You reduce set-up waste _ On-press color measurement values are directly available to your color management process inco_check 21

22 System features System features High-resolution spectral photometer provides precise results inco_check s sensor measures within the spectral range of 380 to 780 nm according to the ISO 13655:2009 standard. Combined with a resolution in steps of 1 nm the sensor impressively provides the most accurate measurement results even at printing speeds of up to 800 m/min (2,625 fpm). The precision of the measurement results captured in real-time is the basis of a quick and exact correction of color deviations. Alignment with offline measurement devices guarantees comparability inco_check s sensor is aligned with an offline X-Rite spectral photometer according to the XRGA standard. Thus, the measurement results provided by inco_check correspond reliably with your or your customers offline results. On demand we will align the sensor with any common measurement device. The measurement accuracy is < 0.5 Eab (D50, 20) in either case. Stable measurement conditions allow reliable conclusions According to the ISO 13655:2009 standard, the measurement is carried out on special rollers with a white or black coating. An optional sleeve solution is available for easy cleaning or changing of the measurement background. To ensure the comparability with offline measured values we include corresponding ceramic tiles from the same material in the delivery. In order to maintain the measurement accuracy, inco_check calibrates itself periodically to a standard. This procedure takes place within the sensor head. Consequently, you may install inco_check into the machine frame without any modifications. Additionally, inco_check automatically compensates ambient temperature fluctuations. This also ensures consistently high measurement accuracies. Subsequent integration is also possible With inco_check you may extend your web viewing system webvideo_star as well as your 100% print inspection system twin_check either from the project beginning or subsequently. Thanks to this modularity you only invest in on-press spectral color measurement when needed in your process. Intuitive menu navigation for an easy operation As the comparative color measurement system _icm, inco_check is also characterized by an easy and intuitive operator interface. Thus, your operators may focus on their main tasks. 22 inco_check

23 Functions The operator simply sets up the measuring fields by the touch of a finger. Functions Defining measuring fields With inco_check your operators set up measuring fields anywhere in the printed image simply by a finger touch. Afterwards they may assign specific values to all measuring fields either manually or by adopting measurement values or by the import of CxF3 files. You receive such files from your customer or from a color quality management system such as for example X-Rite ColorQuality or ColorCert. The defined measuring fields can be saved for repeat orders. This allows for an exact reproducibility of results at any time. inco_check clearly displays all measuring fields. inco_check 23

24 Functions x y-color space Clear display of measurement results facilitates quality control inco_check displays the measurement results either as spectral (CIE L*a*b*C*H*) or densitometric (D C, D M, D Y, D K, D ) values. Color deviations are shown as Eab, Ecmc, E2000 and density deviations as D. The history of the measurement results discloses the quality progression. The classification of the measurements as good, warning or error facilitates the quality control. Detailed display of the current measurement data. Data logging function documents the color quality continuously You can save color deviations and errors in a roll log. Thus, the quality of the entire job can still be evaluated later on. If required these logs also serve as a quality proof for your clients. Data export for your color management By a CxF3 data export the on-press measurement results can also be used in external systems such as the color management system ColorCert or in the color kitchen. 24 inco_check

25 Technical data Technical data Area of application Print methods Materialien all types of web-fed printing presses all types of material System performance Max. web speed Max. web width 800 m/min (2,625 fpm) 2,800 mm (110 inch), wider web upon request Measurement sensor Sensor type Spectral photometer Spectral range nm Spectral resolution 1 nm steps Light source Flash tube Measurement accuracy < 0,5 Eab (D50, 2 ) 1 to an X-Rite Repeatability accuracy < 0,1 Eab (D50, 2 ) Calibration automatic, integrated in the measuring head Measuring field size min. 4 x 4 mm (0.16 x 0.16 inch), depending on the material dynamics on homogeneous areas within the entire printed image Measurement conditions Standards ISO 13655:2009, ISO 11664, ISO 28178, ISO 5:2009, DIN 16536:1997 Measurement background White or black according to ISO 13655:2009 Measuring distance 5 mm (0,2 inch) Measurement geometry 45 /0 Measurement results Output color values CIE L*a*b*C*H* Color density values D C, D M, D Y, D K, D, either comparative or absolute, status E/T/A/I Color difference Eab, Ecmc, E2000 Density difference D Types of illumination D50, D65, A, C Standard observer 2, 10 Data export CxF3 1 determined with an X-Rite measurement device calibrated to XRGA by measurement of 30 colors inco_check 25

26 work_flow Satisfy promises of quality reliably work_flow 26 work_flow

27 Benefits Workflow solutions for 100% print quality 100% defect detection waste reduction defect logging defect verification harmonised quality standards maxed out production defect elimination increased efficiency improved process reliability PDF XML XML prepress roll protocol V1 XML roll protocol V2 print quality control (optional) finishing 100% System twin_check 2.0 Options PDF plate_auditor event_logger waste_indicator quality_assistant rewind_navigator Simply better! Your customers are brand owners? Only an intelligent combination of all your production processes allows you to guarantee your customers the required 100% print quality. You eliminate waste efficiently and reliably. By meeting this requirement of your customers, you secure yourself a crucial advantage in competition. 100% print inspection is the pre-requisite for a well-organized workflow. As a consistent quality control device it provides you with important information regarding print defects. This information allows you to significantly increase your process reliability. If waste occurs during production, you may tag it automatically during the printing process or remove it. You would like to remove waste in a following process? For this purpose, each defect is documented. But not every print defect you would like to see during production automatically causes waste. An optional step offers the possibility to re-evaluate the defect log in order to get the maximum out of the production. The defect log is the basis for your rewinder control so that it may operate at maximum speed and stop right at the spot where waste is to be removed. In short: eltromat s workflow modules provide reliable defect elimination without gaps. At the same time they make this process as efficient as possible. Already during set-up your operators compare the pre-press PDF to the actual print image. Thus, defective or wrong printing plates/ cylinders are recognized at the earliest stage possible. work_flow 27

28 Options PDF plate_auditor prevents faulty production Even when operating with great care it is not possible to completely exclude the introduction of defective or wrong printing plates/cylinders into the machine. In this event, a high amount of waste occurs. The PDF plate_auditor compares the pre-press PDF files with the printing image of the machine. By means of a special structural comparison, it reveals defects of the printing plate/cylinder as well as wrong languages or contents early during the make-ready phase. This allows you to reduce expensive waste to a minimum. The PDF plate_auditor shows clearly deviations between the acutal print image and the PDF from the pre-press. This module is available only for twin_check. waste_indicator delivers accurate defect signals Regardless if a system to tag waste is installed in your printing press, if a material remove is initiated or if another process is to be informed with regard to waste, the waste_indicator reliably carries out this task. It provides an accurate 24V signal for the whole web or alternatively for up to 12 lanes separately. 1 In automatic mode you operators determine for which defect classes a signal is provided by the waste_indicator. Thus, they can concentrate on other important tasks. In semi-automatic mode they activate the signal output specifically for a defect after the defect alarm has occurred. So, at all times the decision is up to them. Activation of the defect signal output based on specific defect classes (1). event_logger provides a log without gaps A consistent defect log is the key to a successful waste elimination. For each roll produced, the event_logger captures all detected defects related to the lane by recording the defect class, running meter and the defect image together with the corresponding reference image. In addition to that, further process-relevant information such as for example a change of the inspection sensitivity, are being kept. With the quality_assistant, the roll logs can also be visualized at a different work station or printed out. Those logs can also be of great help in case of any customer complaints later on. Display of the roll protocol with information about the defect class and running metre. 28 work_flow

29 Options quality_assistant harmonizes quality standards Not every defect detected during the printing process automatically means waste. With the quality_assistant based on the roll log you quickly and efficiently evaluate the quality of your product according to your overall quality criteria. This can be carried out either at a central workplace or directly at the rewinder. Thus, you make the most use of your production output. 2 The quality_assistant displays the defects provided by the roll log in a clearly structured way in the form of a roll map. A classification according to color informs you about the defect s level of severity. Immediately after selecting a defect, the monitor alternately displays the defect image and reference image. Thus, your operators may quickly and simply decide, whether a real defect has occurred. Individual defects or defect groups can be defined as being irrelevant. Also, by means of one click your operators may classify single areas or complete lanes as waste. Simple shortcuts allow an intuitive operation. Usually, one roll log is handled in less than a minute. rewind_navigator increases finishing efficiency Based on the roll log, the rewind_navigator triggers your rewinder in a way that the defects to be eliminated are placed precisely at the splice table. Until the next defect, the rewinder continues operating at maximum speed. This saves precious time. 1 Roll map with defect position and level of severity (1), alternating display of defect image and reference image (2). 2 1 Depending on the configuration, the operator may decide by means of a skip function if a detected defect is to be eliminated or not. Roll map with defect position and level of severity (1), display of the next three defect images (2). work_flow 29

30 Modules For individual requirements Further modular options 30 Modules

31 Modules User interface, inline color measurement trend analysis of the color values and color deviations E Comparative on-press color measurement _icm A good grip on color: How to maintain the necessary color constancy! Providing a consistent color scheme at all printing units throughout the entire printing job is still one of the most difficult tasks in the printing technology. This applies particularly to web-fed printing with high print speeds and the difficulties of a visual inspection. By using the _icm module for the inline color measurement of color deviations, the operator is able to define measuring points simply at any desired position in the image even in the color bars and color gradations. The measuring results are visualised and logged for the operator as individual measurements and trend analyses. The _icm module completes the automatic quality inspection. On the basis of the CIE-LAB color space _icm determines: E / E cmc L a / b C / H Additional functions: _ Tolerances are individually selectable for each measuring point _ Display of tolerance deviations in two alarm levels _ Saving the job data for identical repeat jobs _ Measuring points directly in the design _ Current measurement and color gradation diagrams _ Logging of the measuring results Color drift _icm 31

32 Modules Sampling inspection _sis Detecting print errors fully automatic: Improvement of production quality increases customer satisfaction The continuous inspection of the print image is very significant in a modern and high quality production environment. The _sis sampling inspection system is dedicated precisely to this situation. The eltromat inspection module compares the current print to an automatically saved reference image. The scan mode is activated by simply pressing one button. Occurring errors, such as _ Register deviations _ Doctor blade streaks _ Missing print _ Splashes _ Hickies _ Toning are detected reliably, indicated visually and acoustically and logged. adapted to the current production and thus adjust perfectly to the requirements. Print errors already recognised will be inspected again with a changed sensitivity. This allows the accuracy of the setting to be checked. This technological advance helps the printer to achieve an even higher degree of reliability. While the operator attends to other important tasks, the identified print errors are recorded and logged. The homogeneous backlight flash allows the inspection of transparent materials without false alarms as a result of occurring shadows or reflections. The results can thus be retrieved at any time and are retractable. The inspection sensitivities can be individually 32 _sis

33 Modules User interface, barcode verification trend analysis with classification Barcode verification _bc Controlling the barcode: How to ensure the legibility! Due to the automation of cashier systems and related requirements for reliability in scanning, the consistent print quality of barcodes is becoming more and more important. Minor deviations are reliably detected with the _bc module, which helps to avoid reading problems later on. The product quality in general is increased and costly claims are prevented. The automatic detection of the direction, centering and magnification of the barcode makes the inspection reliable and easy for the operator. The real-time classification and the control of a status lamp ensure an optimum overview during the entire production. The use of the barcode module _bc offers the highest possible level of reliability for the packaging and label print according to ISO and ISO The use of intelligent software enables the inspection of common types of 1D and 2D data codes (Barcodes, QR-Codes, Datamatrix-Codes). _bc 33

34 Modules Semi-automatic CI Register control regi_touch Fast and precise in the register: Setting of the register without marks! In times where printing jobs are getting shorter, the minimization of setup times of the machine is more and more important. A major factor in the setup process is the register. regi_touch supports the operator at this stage thanks to its intuitive and simple handling. For a reliable setting of the register you just need clear points in the print image, no additional register marks are required. the monitor and simultaneously records the position of each color. To do this you may use the register cross or any other unique point within the print image. With the press of a button the correction of registration will be carried out fully automatic. The assignment can be executed at machine standstill and the correction of the register is done very quickly. Since no registration marks are required sleeves can be used with any printing plate. In addition, this increases the flexibility in production. Simple assignment of reference color and all other colors by finger-tip. With regi_touch the operator simply assigns the reference color and all other colors to the respective printing units by finger-tip on 34 regi_touch

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36 Global experience. Local solutions. sales service headquarter subsidiary exclusive representative/ certified service partner representative Find your local Contact at Innovations for your success! Seeing, what is important _Web viewing _ 100% print inspection _ 100% surface inspection _ Workflow solutions Fine color matching _On-press spectral color measurement Quickly in register _ Color to color control _ Insetting & presetting _ Sensor even for low-contrast colors and varnishes Dynamic in process _ Automation control for web based production lines _ Modular solutions from a single supplier _ Retrofit projects eltromat GmbH Herforder Strasse Leopoldshoehe Germany T F info@eltromat.de Printed in Germany. All specifications are non-binding. The right to make modifications in the interests of technical improvement is expressly reserved.