On the Fly & on the Mark
An on-press video inspection system increases quality, ensures consistency, and cuts waste in a web printer's new market.
Staff -- graphic arts online, 12/1/2000
As part of its expansion into the burgeoning market for high-end direct mail-including a recent short-turnaround job involving three million pieces-Shawnee Systems, Inc., Cincinnati, added a new video inspection system to its eight-unit web press to allow real-time monitoring of image register and color reproduction on both sides of the web at the same time.
Says Dick Rogers, president, "We chose the ProScan 2000 system from BST Pro Mark so that we could be more efficient and competitive in serving the direct-mail market."
Rogers, who says Shawnee's press supplier, Stevens Graphic Corporation, recommended the ProScan unit, adds that Shawnee was attracted to video inspection for other reasons as well. He says, "We especially liked how the unit allows us to monitor registration and color on the fly. While printing at 1,000 feet per minute, we can still check on any part of the job at any time during the run."
Over and under cameras
The two-camera system displays 450 lines of picture resolution for what Rogers calls "superb" picture quality, detail, and color fidelity. It uses two proprietary CCD video cameras--one above and one below the web--and a traversing backstrobe to produce crisp images of the printed piece while it's being printed. The dual strobes also allow viewing of difficult-to-see varnish, lacquers, UV fluorescent materials, or cold seal, explains Rogers.
He continues, "A special feature allows us to see 'through' the web, which is particularly useful for inspecting duplex print. Viewing both sides of the web simultaneously is perfect for managing front-to-back registration. Identifying and correcting problems as they develop cuts waste and saves time."
Press technician Chris Thomas explains, "Before, we used a strobe light to check registration, but it was impossible to be precise while printing at high speeds. With the old system, we'd run the press for awhile, stop it, pull off a sample and look at the form, make an adjustment and start up again, then repeat the process until we got it right.
"Now I monitor the job from anywhere on the press, using the ProScan and its remote control. I make adjustments at each station on an as-needed basis, which ensures continuous accuracy of color-to-color and front-to-back registration."
Thomas concludes, "The video system makes it simple to maintain perfect punched-hole alignment, which is crucial for continuous forms. If necessary, I can turn the monitor around and inspect the run while I'm catching product off the end of the press."
Cutting waste by 4%
Tom Berger, Shawnee's manufacturing manager, says the ProScan system has been both cost-effective and trouble-free since its installation, plus it's easy to learn and operate. Says Berger, "With simplified operation, one person can run the entire machine. Press productivity has soared, and we've cut waste by more than 4%."
BST Pro Mark, which is based in Elmhurst, Ill., supplies video web inspection and web guiding systems to the printing and converting industries. Its ProScan dual-camera video system, available in configurations for a variety of web sizes and applications, is suitable for use on presses producing flexible packaging, folding cartons, labels, business forms, and commercial products.
"We use the system on every job we run, 24 hours a day," says Rogers. "It's remarkable. We've raised the bar for quality, our customers are getting a superior print job, and we've virtually scrapped waste and inefficiency." Rogers concludes, "As we expand further into the direct-mail business, we will certainly add more ProScans."
