by DPS Magazine Staff
Part two of three
As label and packaging providers move towards digital print technologies, the requirements of inspection and verification evolves.
Variability Challenges
One technical challenge comes from variable content. The presence of variable content has resulted in increased processing, requiring systems to become smarter in their evaluation of print, according to John Cusack, product line manager, Inspection Products, Baldwin.
Beyond the introduction of variability, hybrid printing applications introduce the need to treat individual print jobs as multiple, simultaneous jobs. “Often, the performance of two print techniques can vary in quality in terms of color and register stability, which forces inspection systems not optimized for hybrid to adopt a setting based on the lower quality component, potentially missing critical issues in the other. Inspection systems like Baldwin’s Guardian PQV system can be configured with multiple different tolerances and sensitivity settings for different types of print, so no compromise has to be made in print quality verification,” offers Cusack.
Mike Agness, EVP, Americas, HYBRID Software, agrees, noting that variable data can present a challenge, particularly when determining whether it is something that can be ignored or, conversely, requires 100 percent verification. “Many graphic components involve dynamic variable data such as different barcodes or alphanumerical—serialized or randomized—sequences.”
A good quality control (QC) system can even read the data and keep it in memory; for example, to assure a number does not replicate. “That’s imperative for products like pharmaceuticals. What if variable data is incorrect—unreadable, out of specification, or perhaps even incorrectly duplicated? The job can be removed, reprinted and remanufactured. It’s better than releasing the product into the field,” says Agness.
He adds that in many cases an inline QC inspection system needs to inspect an entire print. However, often there are pieces that are, reasonably, not critical to the success of the printed product. “It is imperative for the inspection system to focus on the areas of highest concern. The prepress department takes time to focus on these areas related to the product. Why wouldn’t they also set up this focused inspection? Making sure the system understands the cut size helps because it’s inefficient to consider anything beyond it. That can be a challenge, with the irregular shapes of cartons, and odd-shaped labels. A good workflow—one that prepares art for print—can help to define the important areas or zones to inspect as well as clarify variable data for the data stream that is printed on a digital press.”
Variability also comes in the form of substrates. “One of the biggest challenges in the labels and packaging market segment is the need for fast and accurate inspection across a wide range of (recycled) substrates and printing technologies,” says Dr. André Schwarz, director marketing and documentation, EyeC.
Schwarz explains that industry and retailer standards now require labels to carry more information than just marketing and promotion. “The inspection systems must be able to handle various materials, including different types of paper, plastics, and foils. They should also be capable of detecting defects in various printing processes, such as flexography, gravure, offset, and digital printing. Furthermore, the systems must cope with special effects such as embossing, varnishing, and metallic inks. At the same time, the demands of a label and code are ever changing. Not only are codes used to identify products, but they also combat counterfeiters and gain consumer trust.”
And still it can mean differences in printing processes as hybrid environments become more common.
“Different printing processes, such as flexography, digital printing, and offset printing, each have their own set of challenges. Print inspection systems need to be versatile enough to adapt to these various processes,” shares Senol Feizi, technology manager, director of technology and business solutions, Complete Inspection Systems, Inc.
Productivity Challenges
One major challenge for label and packaging teams is time constraints. “The industry moves at a rapid pace producing thousands of assets daily and in order to meet their customers’ strict timelines, teams need to optimize their processes and operate at maximum efficiency,” says Julie Meredith, head of marketing, GlobalVision.
She says one of the most important processes for optimization is manual proofreading and QC inspections. Automated inspection and verification systems automate these manual processes, reducing inspection times from several hours or even days to just a few minutes. “This empowers labels and packaging teams to accelerate the speed at which they can produce products and content and allows them to get to market faster and more efficiently,” adds Meredith.
Guy Yogev, senior director product marketing, AVT Inspection Product Line, Esko, feels that inspection should be more connected and automated, to address shorter runs, manpower restrictions and training. “It needs to be focusing on reducing waste and wasted time during printing and converting and increased overall savings and efficiency.”
Doron Ben Avraham, business development manager, digital printing and vision inspection specialist, BST North America, a subsidiary of BST GmbH, feels that a key challenge is the integration with digital workflows and fine tuning sensitivity settings to accurately detect defects while minimizing false positives. “The growing complexity of graphic designs, especially with the use of intricate embellishments like foils, holograms, security elements, and UV inkjet applications for print enhancement, adds to the inspection complexity.”
Digital Complications
While there are many benefits to digital printing, as more adoption continues in the label and packaging space, some changes are necessary. “Shorter runs and nonstop printing and job change, are also a challenge for inspection, quality assurance and closing the loop on waste removal before shipment,” says Yogev.
Part three of this series highlights some inspection and verification systems available today.
Mar2024, DPS Magazine
