100% Print Inspection System and 100% Surface Inspection System

This is an intelligent tool designed for the comprehensive inspection of printed and plain substrates like films, laminates, paper, fabrics, nonwovens, and more. It is particularly valuable for machines operating at speeds beyond the perceptual capabilities of the human eye.

The system is equipped with high-resolution cameras, monitors, and cutting-edge AI-based image processing software. It conducts real-time image comparisons with master templates, enabling the detection of imperfections that remain invisible to the naked eye. In addition, the system promptly triggers alerts to facilitate corrective actions during the ongoing production process. Additionally, it includes built-in features like alarms, warnings, and “digital roll-maps” to further enhance the quality control measures.

Frequently Asked Questions for 100% Inspection

A line scan camera-based 100% surface defect detection system is used during the process to continuously inspect the substrate for any deviations. It utilises high-resolution line scan cameras to capture data, and processing software to analyse the surface for defects.
Line scan camera systems capture images line by line, providing high-resolution scans of an entire surface, making them ideal for continuous and comprehensive inspection.
The system can detect a wide range of defects, including holes, dents, dark spots, stains, gels, creases, fisheyes, wrinkles, splices, scratches, coating voids, insects, patches, and shade variations, besides others.
Yes, this system is designed for integration with existing production lines, allowing seamless inclusion in various industries.
Yes, these systems are versatile and can be configured to inspect various surfaces and materials commonly used across different industries.
The systems use dark-field, bright-field and angular lighting besides incorporating adaptive features to handle varying ambient conditions.
Yes, the system's stored data can be used to analyse historical defect patterns, identifying trends for continuous process improvement and maintenance.
A line scan camera-based 100% print defect detection system is used during the printing process to continuously inspect the print for any deviations when compared with print artwork. It utilises high-resolution line scan cameras to capture images, and image processing software to analyse the entire print repeat, ensuring 100% inspection of the production run.
The line scan camera has pixels arranged as a single row. This captures the image line by line as the substrate moves towards the rewinder. The image processing software recreates the print in real-time and analyses defects. Print defects like misprints, misregisters, color variations, streaks, hazing, and any other print related anomalies are detected. The system triggers an audio, visual alert for immediate corrective action as well as registers the defects as an electronic stamp. A roll-map is saved which has the x and y coordinates of each defect.
Common defects that this system can detect include misprints, color variations, streaks, bleeding, missing or extra prints, ink splatters, registration errors, drags, holes and other imperfections that affect print quality.
Yes, the defect detection systems can be seamlessly integrated into any web based printing machine.
Yes, these systems are typically customisable and adaptable for different printing applications, substrates, and printing processes. They can be configured to suit specific requirements and adjusted for defect sizes, different materials, printing speeds, and defect identification parameters.
Yes, the system can be configured to distinguish between critical defects that impact the product's quality and minor imperfections that might not affect the overall usability. This customisation helps in setting different thresholds for defect identification.
The system gives a comparative Delta E value to evaluate colour variation. This value assists in examining the perceived difference between colours.
A roll-map is prepared for each printed roll. The roll-map captures information about a production run, such as roll length, location, and type of defects for quality control purposes. This roll-map can be loaded on an inspection rewinder machine. The QC checker can delete non-critical defects from the roll-map, retaining the critical ones. The final roll-map with critical defects is integrated with the inspection rewinder, stopping the machine at each defect. The operator can cut the defect portion from the roll, thereby, ensuring a defect free final product.
A.T.E. Service team provides technical assistance, software updates, calibration services, besides troubleshooting.
Yes, A.T.E. Service team provides remote troubleshooting, allowing technicians to diagnose issues and provide guidance or support without being physically present on-site.