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

Maximize metal sheet quality & throughput

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

Features
Typical defects
Technical data

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

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DecoSTAR flyer en

Productflyer DecoSTAR English

Filename: MVS-PR-FL-DecoSTAR-EN-062024.pdf
Size: 618 KB
Format: application/pdf

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DecoSTAR EVO flyer en

Product Flyer DecoSTAR EVO English

Filename: MVS-PR-FL-DecoSTAR-EVO-EN-062024.pdf
Size: 499 KB
Format: application/pdf

Download

Print inspection for metal packaging en

Print inspection for metal packaging english

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.

Download case study

CoatSTAR: Optimizing metal sheet coating

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.