Machine Vision and Web Inspection
Next Generation, Connected Print Inspection Workflows enable data driven decision-making to optimise business performance
By John Cusack, Baldwin product line leader for inspection, colour, registration I
n its most basic confi guration, web inspection is simply a set of cameras mounted over a printed substrate, with software that alerts press operators when a print defect is detected. Today’s more advanced inspection technologies apply smart algorithms and utilise data connection to a comprehensive defect management workfl ow. Inspection workfl ows have recently grown far more sophisticated, delivering an immediate impact on effi ciency and profi tability.
Knowing where defects are and having the tools to remove them greatly reduces the risk of returns, litigation, lost business and a damaged reputation. Printers seeking a competitive advantage are leveraging new inspection technologies to meet brand owners’ growing expectations and win new business by off ering defect-free, perfect print quality.
For wide web presses, Baldwin has introduced its new Defender comprehensive inspection and defect-tracking solution. The advanced, data-connected workfl ow gives printers the ability to make strategic decisions based on facts. With the tracking workfl ow, it is possible to make tactical decisions about which defects do and do not need to be removed, based on print customers’ specifi cations.
The cornerstones of this new workfl ow are Baldwin’s fourth-generation 100 percent inspection system (Defender 100 percent Inspection) and its recently launched next- generation web viewer (Defender View). These systems can work independently or in combination to provide real-time detection of defects such as spots, streaks, colour shifts, hazing, wrinkles, pinholes, contamination and any other random defects. Operators are alerted to errors and can take corrective action in real time to minimise waste generation. Defect positions, classifi cations and images are recorded and can be accessed at post- press processes. The system inspects all types of materials and substrates: fi lm (opaque, to transparent, to metalised), paper, board and foil. Defender Data Central then imports and archives visual maps of each inspected job. Quality-control operators can analyse defect distribution, count and type. Out-of-tolerance areas are identified for removal and job-based quality reports can be generated. At the back end, Defender Waste Manager can interface with rewinding, slitting and sheeting equipment to automatically control when they stop/reject, allowing for fast and easy removal of defective material. Defect location data
speeds up the converting process by allowing operators to fast-forward to the exact location of the defect within a roll.
For narrow web presses, Baldwin offers the PQV 4.0 100 percent Print Inspection, which can inspect all types of materials and substrates and provides unique “Object-Based Inspection” throughout the entire printing process, ensuring tighter tolerances and fewer false defects. Areas of interest on the printed substrate can be defined for enhanced or reduced levels of inspection. The PQV 4.0 defect tracking workflow can simultaneously collect data for multiple presses and jobs, even across multiple plants.
Advanced print inspection and defect management workflows are essential to keep pace with brand owner expectations. The good news is that the return on this technology investment is fast and easy to quantify. Printers who realise maximum yield and maximum profitability job after job are those who can ensure individual print customers’ expectations are met through data driven, tactical decision making. With these workflows, it is possible to deliver anything from just “good enough” up to defect-free products depending on your and the brand owner’s needs.
40
September 2024
www.convertermag.com
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