The challenge for inline quality control lies in the speed of the process. Two major factors become prominent. One is the requirement for substantial image capture and processing capacity within the measurement system. The other is the critical management of waste levels by dynamic differentiation between false rejects and real waste, as well as the continuous adjustment of preventive measures to minimize waste.


Typical REGISTRON iQ 300 installed on a LEMANIC press

Inline printing and converting has the advantage that individual non-conforming packs can be tracked down. Two different concepts coexist here: tracking the defective product with manual sorting, and automatic in-line ejection.
 
The benefits of having such a system are twofold:

• The user saves money by avoiding waste
• They deliver consistent quality

Tobacco packaging represents one of the most demanding fields with regard to quality requirements, largely because brand integrity is at stake. This is why Shorewood Packaging, a business of International Paper, after extensive tests, made the decision to install the newest generation of 100% inline quality control equipment, the REGISTRON® iQ 300, on all their BOBST LEMANIC production lines at their Danville VA plant. 


Generic examples of streaks on packaging
 
The new device has a unique digital filter combined with a special algorithm developed by REGISTRON that allows the detection of small dense streaks and large pale streaks with consistent efficiency. The same algorithm also enables the so-called sub-pixel detection, i.e. spots smaller than the physical camera resolution can be detected, depending on the density of the color.

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Bobst SA, Lausanne, Switzerland, October 2009