Inspection Rewinds Step Up to the Plate

Operators can do more with less with inspection rewind systems.

BRING UP THE subject of inspection rewinds and people don't automatically think Derek Jeter—for obvious reasons. But a closer look reveals it's not as far-fetched a comparison as some might believe.

Jeter, the New York Yankees' short-stop, has earned several accolades for his all-around ball playing ability. He earned 1996 American League Rookie of the Year, 2000 World Series Most Valuable Player, 2000 All-Star Game Most Valuable Player, and 2002 ESPY Play of the Year. He's not flashy or cocky, but he's turned heads during his 10-year career for his consistency and aptitude, carrying a career fielding percentage of .975 and a career bating average of .314.

Inspection rewinds aren't full of razzle-dazzle either, but they are the all-around, can-do-it-all equipment of the package printer. They do everything from rewinding rolls and inspecting webs to slitting, counting, and diecutting—on a consistent and high-quality basis. In some cases, inspection rewind features help companies expand the range of substrates they can handle, as well as open up new finishing techniques to their customers.

One example of this is how today's new and improved inspection rewind systems equip converters and printers with the ability to handle all kinds of packaging materials. As brand owners turn to new and unique film substrates to help with product differentiation, their business partners have to have equipment that can offer better control of the web during the inspection rewind process.

According to Nick Knezic, sales and marketing manager, KOR Engineering Inc., slippery and extensible substrates like unsupported films and clear-on-clear labels, call for better motor drive and tension control systems. With this point in mind, KOR Engineering recently refined its inspection rewinders to help label converters and printers extend their offerings to include flexible packaging, Knezic said.

Another significant improvement in inspection rewind equipment has come by way of better embedded micro controller-type technology, said Ron Suenram, product manager - web guiding & inspection, Fife Corp. "The embedded micro controller has greatly improved over the last several years," he said. "These improvements have allowed better image processing, which has enabled us to move away from PC-type technology. The benefit with embedded micro controller-type technology is that you have more control over design. As we all know, PC-type technology is heavily influenced by Microsoft and Intel, which can change several times over the typical life of a product. These changes make product support and backwards compatibility very difficult and/or next to impossible for suppliers of video web inspection systems."

Tension and motor control, as well as enhanced vision processing has helped converters and printers increase business opportunities. Simplification of the finishing equipment has also assisted in this effort, explained Jaime Dagnino, Arpeco sales representative.

"As the need for greater flexibility in material and web handling solutions increased, we worked on keeping operator duties as simple as possible, providing quick job set-up features, eliminating the need for subjective data entry, and providing a friendly interface and machine ergonomics," Dagnino said.

"The key to productivity in today's challenging markets is in the ability to implement the latest that technology offers (like motor drive and vision systems), while keeping inspection rewind systems simple to set up, maintain, and operate," he added.

Read on for some of today's most advanced inspection rewind equipment:

Fully integrated inspection system

AB Graphic International

www.abgint.com

AB Graphic International's flytec 100 camera inspection rewinder with an Imaje S7 inkjet printer for underside printing permits label numbering to proceed simultaneously with inspection and control in one operation. Print defects and missing labels, when detected, are positioned in the operator's field of vision for rectification. The system is specifically designed for final inspection, finishing, and numbering of single-track label flows at speeds up to 150 m/min. and includes full PC-based camera barcode reading option for all popular codes with full FDA compatibility. The flytec 100 is a genuine multi-purpose rewinder that is also suitable for winding and splicing small reels, winding of very soft film and paper reels, and 100 percent single-track barcode inspection and label numbering. The fleyeVision Standard Pharma Option printface inspection system has a full range of logging and reporting functions that provides 100 percent inspected, finished product, and virtually eliminates human error.

High-speed inspection rewinder

Arpeco®

www.arpeco.com

Arpeco's PREMIER combines the worldwide proven features of the TRACKER® with larger roll-handling capabilities, faster run speeds, and more sophisticated web tension management. PREMIER features include 30˝ unwind capacity, 935 fpm machine speed, fast-acting electro-magnetic brake, Arpeco clutch with four independently selectable friction pads, and a Web Advance Unit with pivot retraction for full rewind diameter capability. One of the many optional extras available with the PREMIER is the Dynatrak™ counter and control system, which includes ATMS (Arpeco Tension Management System) with rewind tension control, auto-set-up Arpeco counter sensor with see-thru and reflective mark counting capabilities, optimized counter slowdown, 100-job memory, and secure count capability, among other features. Arpeco offers a full range of price positioned solutions from custom-designed clutching systems and closed loop tension systems, to integration of motor drive technologies, including AC vector, stepper, and servo motors.

Compact web inspection with powerful features

Fife Corp.

www.fife.com

Fife's InPrint Video Web Inspection is an all-in-one web viewer to help operators monitor print quality. InPrint integrates the camera, control panel, and microprocessor into a single, compact, industrial grade housing. There are fewer components to install and all cables have a connection on both ends to simplify the wiring process. 24x zoom and advanced features allow for prompt detection of the smallest variations in print or register settings, so they can be corrected before they appear on the final product. A high-performance imager maintains an optimized resolution of 800 x 600 pixels at a refresh rate of 72 Hz, delivering an image that is unmatched in sharpness and reliability. Freeze frame functions make the InPrint easy to operate.

Inspection rewinders designed for films

KOR Engineering Inc.

www.korengineering.com

KOR's FW series of inspection slitter/rewinders is designed for high-speed inspection, slitting, and rewinding of unsupported films, pressure-sensitive label stock, and tag stock. The FW series also enables label printers to extend their capabilities into low-volume/high-quality flexible packaging applications like bottle wrap and pouches. The FW series inspection slitter/rewinders are equipped with large 50˝ OD unwinds, 24˝ OD duplex rewind, layon rolls, closed loop tension controls, and dual AC drives at the rewind as well as a cartridge slitter. Optional equipment includes Vision system inspection, differential rewinding, a variety of slitter cartridges, waster rewind, and many more.

100 percent automatic inspection on rewinds

PC Industries

www.pcindustries.com

The Viper Printing Vision System® designed and manufactured by PC Industries provides printers with the ability to inspect 100 percent of their web for printing defects. The Viper uses high-resolution digital "area scan" cameras to detect print defects such as missing punctuation, broken characters, register, and color variation on printing presses and inspection rewinders at full web speeds. On press, the Viper will alert the operator of print defects and automatically stop the defective printing. On the rewinder splicing table, it alerts the operator for easy removal. The Viper also provides accurate counting, and full reporting and documentation in compliance with FDA 21 CFR Part 11 requirements.

Inspection rewind tables

Retroflex, Inc.

www.retroflex.com

Retroflex designs inspection lines for manual visual inspections. The company can integrate the latest in advanced detection systems to create custom-designed inspection lines to suit each individual client's needs. Every feature in Retroflex-designed equipment is engineered to provide the highest level of quality, reliability, and performance regardless of the customer's purpose.

by Kate Sharon

Associate Editor