by DPS Magazine Staff
Part one of three
As digital adoption continues in the label and packaging segment of print, inspection and verification systems have new challenges to consider. These center around shorter runs of more complex pieces must remain error free to ensure quality, accuracy, and compliance.
Senol Feizi, technology manager, director of technology and business solutions, Complete Inspection Systems, Inc., points out that print inspection systems need to accommodate frequent job changes and ensure rapid setup and calibration. “Print inspection systems should provide value in terms of reducing waste, improving efficiency, and preventing costly errors.”
Digital Growth
As digital print adoption accelerates in the labels and packaging segment. Dr. André Schwarz, director marketing and documentation, EyeC, sees a significant shift in demand for inspection systems.
He explains that these systems must handle higher inspection speeds to keep up with faster production rates and support variable data printing. Color consistency and accuracy are crucial for maintaining brand image and quality. Additionally, coding and labeling technology is advancing to maximize productivity and reduce operational costs on the production line. In addition to enabling real-time defect detection, increasing efficiency, and reducing costs, these systems must provide real-time reporting and monitoring.
“The growing complexity of label materials and packaging types is one of the biggest evolutions in the industry we have seen. The variety of packaging that gets scanned has grown in complexity 100-fold over the last five to ten years,” agrees Julie Meredith, head of marketing, GlobalVision. Beyond traditional print quality considerations, vision and inspections systems now need to excel in variable data verification, ensuring color accuracy, and mastering complex pattern recognition, she adds.
There has also been a shift towards shorter print runs and heightened customization, requiring inspection systems to seamlessly operate in high-mix, low-volume production environments. “Real-time inspection capabilities are now imperative, enabling the early detection of errors and defects in the production process, minimizing waste, and optimizing efficiency,” says Meredith.
Given the increasing significance of digital print, there’s also a growing demand for variable data inspections, particularly for accurate barcode verification. “The prevalent use of quid response (QR) codes for brand promotion requires inspection systems to offer swift and efficient barcode inspection solutions,” offers Meredith.
Feizi agrees, noting that with digital printing, there’s a greater emphasis on verifying variable data, such as personalized information, barcodes, and QR codes.
Further, Doron Ben Avraham, business development manager, digital printing and vision inspection specialist, BST North America, a subsidiary of BST GmbH, an elexis company, points to the critical need to handle variable data and security printing for anti-counterfeit and tracking purposes effectively.
Prepress Considerations
Digital printing has enjoyed significant growth over the years in labels and narrow web packaging applications. “Volume-wise, there has been around a 15 percent growth in digital label printing and around 40- to-50 percent of all label presses sold today are digital or hybrid, so it’s clear the market is growing significantly,” offers Guy Yogev, senior director product marketing, AVT Inspection Product Line, Esko.
Like with all digital adoption, there are demands for faster setups. “At HYBRID Software, we see the adoption of digital printing and increased inspection are definitely evolving. As a prepress company, we receive more questions from the inspection system companies. There are many specifications that are pretty much exclusive to packaging. Some are color definitions. Another is knowing when a color channel may be dedicated to varnishes or die lines; not for print,” notes Mike Agness, EVP, Americas, HYBRID Software.
On the other hand, the market is fragmented with various print technologies and many different workflows for printing and finishing.
Yogev sees a few challenges for inspection in digital printing as well as converters. He says going digital usually means separated steps and stations for printing and converting, compared to a single pass using inline flexographic technology. “This is challenging by itself, but also raises a question regarding inspection and the best position to install it, on press, or at the end of the finishing line, etc.”
Digital print technologies also mean different type of print issues. Inkjet problems such as weak or missing nozzles, color variations, or blanket and oil drips in ELP technology are just a few examples that Yogev provides.
Required Evolution
With digital printing methods, labels and packaging companies can print more, faster, meaning the need for automation is crucial. “Human labor will likely never be replaced, but systems that focus on getting the tedious tasks out of the way with greater ease are in high demand. This will allow teams and individuals to focus on more important, strategic tasks and projects,” says Meredith.
As digital printing exponentially increases production speed, verification and inspection systems must integrate built-in intelligent capabilities to match the new speed benchmark. “Beyond error detection, there’s a growing market demand for systems preventing errors from being introduced initially. This emphasizes the vital role of artificial intelligence in enhancing the capabilities of inspection systems, aligning with the evolving dynamics of digital print technologies,” shares Meredith.
Part two of this series discusses common challenges facing inspection and verifications systems as they target digital label and packaging production environments.
Mar2024, DPS Magazine
