Machine Vision and Web Inspection
Maximising machine productivity and boosting quality
Inspection systems have been used in the printing and converting industry for many decades now; we see new generations come and go.
A
s early as 1940s we saw the rotating mirrors optimised on roll-to-roll presses. That was soon followed using high frequency strobes, followed by sampling- based viewing systems, then the active ‘auto defect detection’ sampling-based systems and fi nally the full web width, full print repeat 100% inspection solutions. If we look at the milestones and technology stepping stones to-date, the progress can be seen: • Rotating mirror viewers used from the 1930s through to the 1990s;
• Stroboscopic viewers used from the 1970s through today;
• Camera based vision viewers, introduced in the 1980s;
• AOI Sampling became the buzz in the 1990s; • AOI 100% print inspection in colour took off in the 2000s; and
• Cloud based networks using commercial scanners Historically printing is and has been a material- intensive and relatively low-margin industry. Printers are under continuous and increasing pressure to maximise productivity and improve and boost output quality while at the same time reducing production costs.
Even a small or fractional reduction in waste levels can have a signifi cant impact on the printer’s
profi tability. Subsequently make your web press more profi table.
In a recent TruColor end-user survey, 91% of all responders reported an average waste reduction of 15% after the successful installation of a high- resolution image output sampling-based viewing system. Additionally, 100% of all responders reported positive, measurable improvements in at least one or more of the following: reduced set-up time, press speed increases, quality improvements, overall press room productivity improvements and the noted waste reductions.
Today’s newest digital camera technology provides ultra-high image quality yielding crisp details, extra sharp colour reproduction and accurate colour contrast – all of which are necessary for quick, easy, and precise print inspection. DIGITAL Advantages Include:
• 4X greater image resolution, yielding crisper, clearer images proven time and time again to yield better inspection results;
• Larger LCD display monitors – easier to see at all distances for improved inspection;
• Improved performance of advanced electronics and remote diagnostic capabilities; and
• Operator friendly controls contributing to ease of operation and quick adjustments.
Today’s DIGITAL systems yield up to 4X more (better) image resolution output, yielding clear, crisp images displayed on a high-resolution LCD image display monitor.
Of course, these advantages alone will contribute to overall improvements in inspection results: waste reduction, increase productivity, improved print quality – all of which help add positively to your bottom-line (increased profi ts). The new DIGITAL output coupled with the high-resolution LCD image monitors are fi eld proven to be an asset to press operators. Not to mention the peace of mind knowing the investment for the system is protected with the newest high resolution image technology.
WOULD YOU INVEST $1 PER PRODUCTION HOUR TO REDUCE YOUR WASTE BY AN AVERAGE OF 15%? We have seen CAPEX justifi cation reports from end-users showing anticipated savings (annual) of more than $10,000.00USD in terms of waste reduction on narrow web machines under 20” for example for the company’s internal Return on Investment (ROI) reports.
On wider web machines with faster production speeds these savings are often compounded. Keep in mind that the AVERAGE waste reduction reported by 91% of our end-user customers is 15% upon installation of a TruColor. Basically, the Return on Investment (ROI) can be as quick as a few weeks, maybe at most several months; consider only $25.00-$30.00 per day investment cost of ownership ($8,000/300 days of production = $26.66) against the payback on waste reductions/savings daily. Obviously breaking down cost of ownership for a sampling-based inspection system even farther, based on only 1 8-hour production shift, that is slightly more than $3.00 per hour (3 daily 8-hour shifts is approximately $1 per hour). If you save only $100 per production day by utilizing high resolution sampling viewing inspection you will be adding $75.00 per day to your bottom line – and making your web presses more profi table. Can your company aff ord to not invest in a sampling-based inspection solution that is proven to maximize productivity, boost quality and reduce waste?
22 May 2025
www.convertermag.com
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