Maximize metal sheet quality & throughput

  • Maximum throughput of high-quality products
  • Improved quality of metal sheet printing
  • Reduced waste and increased yield
  • High level of customer satisfaction
DecoSTAR

Top grade metal printing at top speed

The global demand for metal packaging is constantly increasing. Metal is used in various types of packaging, including food and non-food products, oil cans, jewelry cans, crown caps and closures and aerosol cans. Much of this packaging is printed directly, but is always coated to prevent the metal reacting with the ingredients. Defects in the coating or poor print quality mean that the products are unsaleable at the point of sale.

Printing on metal sheets is a demanding process that places high demands on print quality, coating and material integrity. Potential sources of error such as color deviations, printing errors, impurities, edge and material defects can significantly affect the quality of the end product. Achieving high product quality at high production speeds is particularly challenging.

Our inline printing and coating inspection systems guarantee 100% quality control and process optimization at maximum throughput speed. The ISRA inspection systems are suitable for both offset and digital printing technology and therefore offer a wide range of applications.

Metal printing on steel and aluminum sheets

Our DecoSTAR and DecoSTAR EVO inline print inspection solutions ensure reliable quality control for metal printing on steel and aluminum sheets. These flexible and easy-to-install systems can be used for tinplate or aluminum as well as for high-gloss or matt designs on any type of machine. DecoSTAR EVO can be used flexibly in both offset and digital printing.

Thanks to state-of-the-art LED lighting, our systems reliably identify color deviations and detect register errors, splashes, hickeys, missing color or scratches. They also detect whether ink has been sprayed onto the sealing edges, which must remain free. 

Detecting defects quickly is essential in order to produce as few rejects as possible. 

The inspection starts even before the actual printing process by comparing the future print image with a PDF (golden master) approved by the customer in order to identify defects on the printing plates or incorrectly inserted plates, for example. The make-ready process can also be accelerated. The inspection systems automatically recognize the ink marks and compare them to detect over-inking or too little ink. In this way, color deviations are detected before they become critical.

Defective sheets are ejected thanks to the inspection systems and therefore do not enter a costly downstream process, but can be recycled directly, making the manufacturing process more sustainable.

Our systems offer an intuitive multi-touch user interface that provides high-quality defect data to eliminate serial defects and increase yield. Defect classification software makes it possible to differentiate between relevant and irrelevant defects, thus increasing the saleable quantity.

Thanks to the latest camera technology, our inspection systems offer maximum performance. A modern graphical user interface ensures a high level of user-friendliness.

In addition, our systems ensure an intuitive set-up process for new jobs or the use of repeat files. They provide constant feedback on the printing process, report serial errors and allow quality parameters to be adjusted. Reporting tools provide information on quality data such as the number of defective sheets, the number of defective sheets per pallet and even a defect gallery. They also check the machine speed and provide automatic advance information on upcoming maintenance requirements.

Benefits

  • Offset & digital print inspection with the same system
  • Best resolution for detection capabilities (resolution, colour, etc.)
  • The most widely used inspection system in the metal packaging industry
  • Reduce waste and increase yield
  • High form factor with a high degree of freedom to adapt to any machine on the market
  • High efficiency and long-life LED lighting for years of maintenance-free operation
  • Intuitive set-up procedure for new jobs or use of repeat files
  • 100% inline inspection for each sheet at maximum production speed
  • Continuous feedback on the printing process, reporting of serial errors, adjustable quality parameters
  • Versatile use: for tinplate or aluminium, high-gloss or matt motifs on all machine types
  • PDF-Comparison 
  • Advanced defect classification 
  • Multiple ejection parameters per quality level possible
  • Advanced LED and color camera technology 
  • Integrated data mining and reporting tools for the most efficient process and quality decisions 
  • Inline color monitoring for Delta E or LAB 
  • Inline edge control for permanent inspection of position accuracy 
  • Automatic repetition of Color Measurement bars 
  • Reporting on the machine speed
  • Machine speed reporting
  • Scratches
  • Slugs
  • Splashes 
  • Streaks 
  • Register defects 
  • Missing print 
  • Color deviations 
  • Toning & smearing
  • Doubling
  • Contamination of the weld seams
  • Max. resolution 85µm
  • Max. Speed 10,000 sheets / h
  • Max. Format 1350 x 2000 mm (WxH)
  • Required installation space 400 x 400 x 1400 mm (WxHxD)
  • Can be used before and after drying
  • Digital I/O interface for e.g. ejection, feeder stop, horn, traffic light, etc.
  • Remote maintenance access and reporting via TCP/IP

Download additional information

asdf

DecoSTAR flyer en

DecoSTAR flyer en
Filename
flyer-decostar-print-en.pdf
Size
443 KB
Format
application/pdf
Download

Print inspection for metal packaging en

Print inspection for metal packaging en
Filename
Print-inspection-for-metal-packaging-en.pdf
Size
2 MB
Format
application/pdf
Download

Arkin boosts metal packaging print quality

Arkin, a Turkish manufacturer of metal packaging used for oil cans, food and non-food applications, increases print quality with a 100% inline inspection solution. The high speed of the printing press and the increasing number of colour applications made it difficult for ARKIN employees to monitor production and detect defects. ISRA VISION offered the perfect solution for this with DecoSTAR: the inspection system guarantees 100% inline inspection of up to 10,000 sheets per hour.

arkin-thumbnail

CoatSTAR: Optimizing metal sheet coating

Coating and metal sheets

When coating metal sheets, unsaleable materials, low throughput and high material waste can lead to considerable production costs. A decisive measure to reduce costs is therefore to process only perfectly coated sheets in the printing press. Our CoatSTAR inline inspection system plays a decisive role here by detecting defective sheets as early as the raw material preparation stage and removing them from production. 

During the entire production process, CoatSTAR automatically records data on coating quality, dimensional accuracy and the quality of the weld seams. 

This information can be used both for internal process analyses and as proof of quality for the customer. Through the targeted detection of defects, CoatSTAR helps to reduce waste and increase the sustainability of the production process. CoatSTAR meets the highest quality standards and is characterized by its modularity, making it suitable for any machine.

Benefits

  • 100% inline inspection for each individual panel at maximum coating line speed
  • Easy to operate. Intuitive set-up procedure for new jobs or use of existing job files possible
  • Checking the dimensional accuracy of each sheet
  • Modern LED and line scan camera technology
  • Detection of faulty panels at the earliest possible stage of your metal decorating process
  • Coating inspection ensures the best conditions for a subsequent print run
  • Inline control of the uniformity of the coating surface
  • Constant monitoring of paint quality, dimensional accuracy and weld seams at a glance
  • Multiple ejection parameters per quality level possible
  • Defect marking signal: for mechanical marking of incorrectly coated sheets
  • Automatic masking function
  • Adjustable area sensitivity: individual setting option
  • Extended compensation of sheet movements
  • Scroll sheet detection
  • Scratches 
  • Paint splashes
  • Holes
  • Soot particles
  • Inclusions
  • Lack of coating
  • Contamination of the weld seams
  • Max. resolution 170µm
  • Max. speed 12,000 sheets / h
  • Max. format 1350 x 2000 mm (WxH)
  • Required installation space 200 x 200 x 1400 mm (WxHxD)
  • Can be used before and after drying
  • Digital I/O interface for e.g. ejection, feeder stop, horn, traffic light, etc.
  • Remote maintenance access and reporting via TCP/I

Download additional information

CoatSTAR flyer en

CoatSTAR flyer en
Filename
flyer-coatstar-print-en.pdf
Size
363 KB
Format
application/pdf
Download

Print inspection for metal packaging en

Print inspection for metal packaging en
Filename
Print-inspection-for-metal-packaging-en.pdf
Size
2 MB
Format
application/pdf
Download

Cinbal tackles production costs with inline inspection

Cinbal - one of the largest manufacturers in South America - responds to the high cost pressure in the production of metal packaging with 100% inline inspection. The producer was faced with the difficulty that defects were not only occurring during the decoration process when printing, but also beforehand when coating the sheets. The CoatSTAR and DecoSTAR inline inspection systems offered a solution. 

cinbal-thumbnail

生产分析-数据驱动高效生产

通过网络生产分析平台,您可以一目了然地查看所有产线的系统状态,或详细分析生产数据。通过质量管理系统,您可以分析历史数据,实时监控当前的检测数据,并确定生产过程的未来趋势。

及早发现生产缺陷

利用实时状态信息和自动报警功能,在生产的每个阶段检测并快速查明违反警戒线的原因。因此,您可以快速解决生产缺陷,缩短停机时间,降低生产成本。

预测性维护

通过分析来自传感器和监控系统的实时数据, 您可以预防潜在的系统故障。这样就可以根据机器的实际状态,而不是遵循固定的时间表,主动制订维护计划。这种数据驱动的方法可以减少停机时间、提高整体生产效率、延长生产线寿命,从而节约成本。

优化生产

通过数据仪表板,您可以在现场或远程比较产线情况和产品数据,为优化提供关键见解。这使您能够在价值链上做出明智的专业决策,从而提高产品质量和盈利能力。您可以持续跟踪优化措施的进度,并通过可视化的高级报告进行展示。

您的收益

  • 省时便捷的多产线预览,一个视图显示所有质量相关信息
  • 通过监控系统健康数据,最大限度地减少停机时间
  • 通过监控质量数据,对质量问题做出更快反应
  • 快速消除生产缺陷,降低生产成本
  • 改进维护,减少停机时间,提高整体生产率,延长生产线寿命

主要功能

  • 生产数据和工厂状态概览
  • 从实时数据中获得实时见解
  • 基于网络的解决方案,无需安装客户端软件
  • 阈值监控和警报
  • 面向各部门的仪表盘,可根据客户要求进行调整
  • 可集成相关的第三方数据,并将数据导出到客户的系统

量身定制的服务解决方案和个性化培训

为了帮助您的生产系统高效可靠地运行,满足不断增长的市场需求,我们高素质的服务团队为您提供最优的交流和先进的技术分析。我们全球服务网络,快速、可靠。我们可以确保系统的运行、保养、维修以及分析和优化。

此外,您可以在ISRA学院向我们技术过硬的培训师学习,如何让您的员工时刻掌握最新知识,让系统操作员、产品工程师和质量经理成为真正的检测专家。

联系我们的专家

石潇文
伊斯拉视像设备制造(上海)有限公司 

销售经理
上海
China

电话 : +86 1366 1800 082 

电子邮件: info.china@isravision.com

Steven Shi