Press Releases and Articles
With many manufacturers providing standardized one-size-fits-all inspection systems, catching defects on a higher speed web or sheet often comes with compromises. When running at the highest speeds, standardized systems will often hit a limit in inspection and processing capability. These systems have no choice but to lower sensitivity and allow the passage of larger defects in order to maintain speed. Unfortunately, the printer may not realize their 100% inspection is not providing accurate or consistent defect detection. This can be one result of selecting an inspection system that hasn’t been configured for a printer’s specific application requirements or equipment.
The four key components to reliable high speed inspection
How can you find out which 100% inspection systems will provide consistent defect size detection throughout the full speed range without decreasing sensitivity? First of all, your inspection system provider should include technical specifications for their system along with a written performance guaranty. In addition, four key components of the inspection system should be selected to meet the requirements of your application, integrate seamlessly in your process, and provide you with reliable and accurate inspection. These components are:
- High performance cameras
- High quality LED lighting
- Robust fully developed inspection algorithms
- Powerful computer processing
High-Speed HD cameras and powerful LED lighting work in unison to capture high resolution images of the web or sheet. If either the lighting or the camera are not specified for the full range of your application requirements, the captured image will be lower in quality, especially at higher speeds. Starting with a less than perfect image will result in a less than perfect inspection.
If the image quality is excellent, then it’s up to the systems software and computer processing to complete the inspection.
The inspection system’s software algorithms should be developed to handle the demands of high speed 100% print inspection, along with any added bar code or variable data verification if required. A powerful processor selected for your unique application requirements will ensure that the system can detect and highlight defects accurately.
An inspection system correctly configured for the requirements of your application will accurately and consistently detect defects at high speeds without a variance of defect size. Achieving the high productivity you need without compromising your inspection process is an important step towards satisfying your customers and growing your business!
Eliminate the inspection compromise between small defect size and high-speed
If you are looking for a system that performs at the highest speeds while guaranteeing a consistent minimum defect size, the Guardian PQV 100% Inspection System is the perfect solution to improve your quality and help your business. Click on the button below to discover all the Guardian PQV’s capabilities.
Accuracy is critical to make the most out of your quality control investment and reap process and productivity benefits. PC Industries’ systems are designed to provide that accuracy. We are committed to understanding your application requirements and providing a 100% inspection solution that meets your needs today while providing performance growth for the future.
We will be present at Label Expo Americas at booth 1411 in Rosemont, IL from the 13th to the 15th of September. You can request a consultation during the show by clicking the button below.
Request Consultation at Label Expo Discover the Guardian PQV
Label Expo Series Trade Shows in 2016
Printers and converters across Central and South America have shown great interest in PC Industries’ intelligent and automated inspection systems at Label Summit Latin America. The Guardian LSI was PC Industries’ product highlight, providing printers and converters with automated defect detection capabilities at a low investment. In addition, the excellent networking opportunities PC Industries saw at the show are continuing to pay off. We’re looking forward to continuing this trend at Label Expo Americas in September!
For the upcoming Label Expo Americas show, we will highlight our latest defect detection technology, which allows high speed inspection without sacrificing resolution. We hope this showcase will spark your curiosity, so make sure to visit us at booth 1411 from September 13-15 in Rosemont, IL!
Stepping up from simple web viewing…
Web viewers are the perfect way to implement basic inspection capabilities in your quality control process. PC Industries’ viewers are equipped with high resolution cameras which take snapshots of the web at various positions. With the included HD monitor, the operator gets clear images of the web, and can more easily see any defects, registration problems, or other results of process errors that are present.
The Graphic-Vision® GV series web viewers are easy-to-use and economical web-viewing systems that help identify press-defects. PC Industries standard web-viewing systems are also capable of decoding and displaying 1D and 2D barcodes for easy review.
… to automatic defect detection solutions.
For increased inspection power, efficiency, and accuracy, intelligent inspection systems are a must. These systems provide automatic defect detection and advanced capabilities such as barcode grading, dimensional measurement and gauging, and sequential data verification.
PC Industries’ Guardian LSI is an affordable, entry-level, full web automatic defect detection system. It detects and highlights typical defects such as ink splashes and spots, registration errors, missing labels, unremoved matrix, and more.
For printers looking for more capabilities and power, the Guardian PQV offers full featured inspection. The system finds smaller defects and higher speeds, and provides all the advanced features listed above. By alerting the operator of defects automatically and immediately, the defective product can be minimized, ensuring continuous and measurable quality, customer satisfaction, and a rapid ROI.
PC Industries will present their high speed inspection capabilities at Label Expo Americas
At this year’s Label Expo Americas, we will be presenting our leading edge capabilities which allow for high speed inspection without sacrificing resolution.
This leading edge performance is made possible through the latest high-speed, high-resolution line scan cameras, optimized algorithms for print defect detection, and powerful solid state LED lighting modules.
Curious to discover a high performance inspection system in action? Come visit us at booth 1411 at Label Expo Americas from September 13-15 in Rosemont, IL! To schedule a demonstration, please click here and fill out our online form. A PC Industries representative will contact you soon to discuss your application.
Efficient quality control with PC Industries’ Defect Mapping software
Defect Mapping is a flexible, easy to use software module for the Guardian PQV that helps operators monitor job quality and eliminate defects. By detecting and recording defects early in the printing process, the Defect Mapping software makes it easy to correct defects post-press. It provides a true report of defect free products once job auditing is complete. Automated monitoring of product quality throughout the production process helps ensure that quality products are delivered to your customers. This increases their satisfaction and improves your bottom line.
Inspect: Automate Defect Detection through Defect Roll Mapping
Setup is as easy as capturing an image from the press, training the system, and beginning inspection. On systems equipped with PDF Check, the golden image from the press can be verified against a customer approved master document before inspection begins.
During inspection, the Defect Mapping software will record defects by lane and footage for each roll or sheet. The on-screen grid display provides a graphical representation of the location of defects for each lane, with color-coded indication of the severity of each defect. The operator can view the Defect Map history and accept or reject defects while the system still provides 100% inspection. Defects are displayed side-by-side with the master image for easy comparison. The operator can easily train the system to ignore repeating, non-critical defects for a more efficient run. These settings can be saved and retrieved for later runs of the same job.
Once the job is finished running, the Defect Map can be output to an enhanced PDF report, which logs key job information, images of each defect, and the corresponding master image. The Defect Map can also be saved and automatically transferred to an Edit Workstation, Audit Rewinder, or other finishing machine.
Edit: Remove Defects Before They Reach the Rewinder with the Editing Workstation
To enhance quality control, information collected from the press run on the Defect Map can be edited at a dedicated Defect Map Workstation, which can be located anywhere in your facility. With the Defect Map Workstation, the Defect Map is automatically transferred once the job is complete. The operator can confirm or remove defects from the Defect Map before the job is sent to a post press process for defect correction. The productivity of the slitter/rewinder is improved by eliminating unnecessary starts and stops due to non-critical defects. Editing workstations can accept information from multiple presses, and feed multiple slitter/rewinders.
Audit: Finish with Perfect Product using the Control Workstation
The Defect Map Control Workstation integrates with nearly any finishing machine, including slitters and rewinders. The system includes the timing circuitry and output controls necessary for machine control, flagging or marking devices, or defect diverter timing. Additionally, for sheet-fed and similar applications, sheets can be sorted based on several criteria, including position of defect on the sheet and type of defect.
In a typical rewinder application, the Control Workstation will signal the machine to decelerate and stop the defective print at the splicing table or other preferred location. Placement is very accurate, even at high speeds. The defective label is displayed for review on the monitor, allowing the operator to toggle between the sample and master display and magnify defects.
FTA Info*FLEX 2016
Info*FLEX was a great trade show again this year. It attracted nearly 2,000 visitors to Fort Worth to participate in the show and Info*FLEX Forum seminars. Over two days, professionals presented tools necessary to support successful package printing and converting operations, while benefiting from intensive networking and live demonstrations of running machinery.
PCI showcased two of their popular products, the Guardian OLP and GV-Spectro. The Guardian OLP yielded great interest from visitors as it provides a complete off-line proofing and inspection solution that helps operators control even the smallest pre-press and pressroom mistakes.
The GV-Spectro – an in-line absolute color measurement system – combines the advanced capabilities of a web viewer with a powerful spectrophotometer. It monitors the web and color values in-line, even at high speed.
In addition to the presented products, many customers and visitors were interested in talking about PC Industries’ capabilities in higher level print inspection applications, including dimensional gauging and variable data verification.
Jack and Gerry would like to thank all visitors who stopped by our booth, and we look forward to next year’s Info*FLEX in Phoenix, Arizona!
We’re keeping up our busy year of attending shows, make sure to visit us at the following exhibitions!
- Converters Expo, Green Bay, WI – April 13, 14 2016
- Label Summit Latin America 2016, Cartagena, Colombia – April 26, 27 2016
- Label Day, Toronto, Canada – May 10 2016
- Label Expo Americas 2016, Chicago, USA – September 13, 14, 15 2016
Guardian OLP: KDV Label’s choice for narrow web Flexo printing
KDV Label provides labeling solutions for markets such as consumer goods, beverage, food, chemical petroleum, and more. KDV has strict quality requirement when it comes to supplying their customers with labels.
Defects can always happen in the pressroom. Preventive measures are the best way to protect a company from shipping labels with defects and having dissatisfied customers. KDV Label implemented PC Industries’ OLP Off-line proofing system to counter these issues at the source. For Nick Scharber, the Prepress Manager at KDV Label, “the system itself, ease of use, and access to the developers and support,” prompted them to partner with PC Industries. “After evaluating many inspection systems for our printed label products we chose PC Industries’ OLP system for our needs based off of the features, cost, and personnel. We have been using their OLP inspection system for over a year now and couldn’t be happier with our decision.”
In preparing for the press run, the Guardian OLP is used to verify register and job sign-off. By comparing press samples to the customer-approved master, the system helps guarantee plate quality and print job integrity. As for ease of use, these inspections typically only take a few seconds to perform, and can be set up with only a few clicks, to assure no interruption in the production process.
While a couple small issues arose, Nick recalls that these were taken care of within a day, accompanied by a very positive customer support experience, thanks to one of PC Industries’ engineers, Nick Baker. “Any struggles we had have been addressed quickly and we even have made specific requests for modifications within the software that were implemented by PC Industries,” says Nick Scharber.
The Guardian OLP has become an efficient tool for KDV Label when inspecting their production, ensuring defect free labels to their customers.
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PC Industries Acquires VSL
PC Industries and Verification Systems Limited (VSL) have reached an agreement for PC Industries (USA) to acquire VSL (UK).
Both companies are in the process of merging the companies, resources, and technologies.
With their combined expertise and longevity, they will provide quality control systems with unparalleled inspection performance for demanding industries and applications world-wide. PC Industries and VSL endeavor to continuously expand their global network of distributors, representatives and support.
The merger will also allow PC Industries to provide support and service to its European clients from the United Kingdom.
PC Industries has been in business since 1975. Throughout the past 40 years, they have built a strong reputation through reliable, accurate, and powerful inspection systems and world-class customer support. They manufacture the widest range of print quality verification systems of any inspection system manufacturer.
Verification Systems Limited (VSL) is one of the world’s leading specialist in the development and manufacturing of Inspection and Verification Systems for Security Print including bank notes, cheques, certificates, licenses, brand protection labels and stamps. The first of these systems were developed in 1976. Their staff has years of experience in providing and servicing simple to complex inspection solutions for variable printed data including serial numbering and barcodes.
Guardian PQV ad as seen in several major publications, including Label and Narrow Web and Labels and Labeling
Appeared in May and June 2015 in Label and Narrow Web.
Trade Show EventsPC Industries is proud to be active in the label, pharmaceutical, printing, and converting industries. We are always looking for new ways to communicate with our customers, and find that trade shows provide unique opportunities businesses to network. Click here to see what trade shows we will be appearing at. We hope to see you there!