Print Process Management System - BST Sayona Automations

Print Process Management System

Productivity And ROIIn this day of global competition, faster press speeds, constantprice pressure and demands for defect free product from yourcustomers, printers and converters need to use every possiblemeans to achieve continuous process improvement. Today’s printingpresses run at speeds that were unheard of just a few years ago.The potential impact to your productivity and bottom line is huge.But without an effective on-press inspection and process managementsystem, the down side potential is even greater.PREMIUS digital 3 Chip was engineered from the start as a tool to helpoperators manage the printing process. The unique combinationof the most advanced digital inspection technology in the world,with an easy to use graphic user interface, generates productivityimprovements and bottom line impact that will allow you tocompete and win in today’s dynamic market place.Savings in €/$500.000450.000350.000300.000250.000200.000150.000100.00050.0000I I I0,05 0,1 0,2 0,3Substrate Costs per m 2 in €/$Maximize ProductivityRun at the highest possible press speeds with confidence thatprint quality is being effectively monitored on a continuous basis.You will realize greater “up” time from the press, less stoppingand starting and be able to get jobs into proper register and colorquicker … all with minimal effort.Minimize WasteIdentify and eliminate print defects, color deviations, register shift,and bar codes that will not scan in real time, and you will realize anoticeable reduction in material waste.Reduce Change Over TimeResearch has shown that the Register Pre-Setting option can savean average of ten minutes per job! At five jobs per day, thatamounts to over 300 additional productive hours of press timeper year.Optimize QualityMonitoring print quality continuously during every roll, allows youto identify and eliminate print defects quickly and efficiently,resulting in maximum finished quality product for your customers.Our new extra large field of view means a greater amount of theweb is inspected, more frequently than competitive systems.Effective Process ManagementIdentify and eliminate print defects on the fly. Guarantee colorconsistency from roll to roll and job to job. Avoid fines for barcodes that do not scan.Easy To Use Means A Tool That Is UsedYour operators will thank you for investing in such a high tech toolto help them be more efficient and productive.Generate A Substantial Return On InvestmentProduce more deliverable product at a lower cost.Substantially reduce start-up time (and material) for every job.Eliminate reruns and credits for non-conforming product.Satisfied Customers Mean Repeat BusinessDeliver the highest possible product to your customers every day,and they will reward you with more orders.Proven Performance WorldwideIt‘s a fact, BST has more web inspection systems installed andrunning successfully than any other company in the world - over15,000. It is also a fact that BST has been supplying systems withprint process management since 1994. We have more processmanagement systems installed and running successfully than anyother company in the world – over 1,500 and growing fast!2

The World´s Most TechnicallyAdvanced SystemTheCompetitionPremius digitalPremius digital 3 Chip3 Chip analog1 Chip digital3 Chip digital100% DigitalPREMIUS digital 3 Chip is the worlds first web inspection andprint process management system to integrate digital cameratechnology, 3 chip color reproduction and a new extra largefield-of-view. This unique combination of state-of-the-arttechnologies allows PREMIUS digital 3 Chip to harness the full powerof process management (defect detection, color monitoring, etc.)as never before, while making huge strides in operator functionalityand ease of use.Camera Resolution ComparisonDigital 3 Chip Camera ResolutionPREMIUS digital 3 Chip uses a digital 3 chip camera with 4.2megapixel resolution, which is more than 300% better than allother systems on the market, including the finest 3 chip analogsystems. This means image quality that is photographic, with crispdetail, sharp contrast and rich vibrant color.The new camera technology has a direct impact on processmanagement functions – resulting in defect detection and colormonitoring that are more powerful, capable and reliable thanever before; and find defects other systems do not find.Superior Dynamic RangeThe new camera technology used in PREMIUS digital 3 Chipfeatures a Dynamic Range - the ability to show light and darkdetail at the same time - that is substantially better than anysystem made. This allows sharp contrast along the entire colorspectrum, and in particular at the high and low ends where it ismost useful to a printer, resulting in superior, more reliable printdefect detection.Magnified image detail taken with analog 3 chip cameraused in most high end video systemsMagnified image detail taken with digital 3 chip cameraused in PREMIUS digital 3 ChipDigital Data InterfaceA common and troublesome problem with analog defectdetection systems is the loss of data that occurs during imagecapture and processing. But because PREMIUS digital 3 Chip usesDigital Data Transfer (DDT) technology, zero information is lostduring image capture and processing. The data stream is pure,resulting in greater accuracy and reliability for all processmanagement functions such as defect detection, color monitoring,bar code verification or register pre-setting.Analogue Data TransmissionDigital Data TransmissionElectronic NoiseDocumented Color Management EffectivenessAutomatic color monitoring too, is greatly improved by the use ofthe new camera technology. With three times as many pixels tomanage color, PREMIUS digital 3 Chip will sense far more subtle colordifferences and gradiations (vignettes) than any systemon the market.Unique Shutter TechnologyFree shutter timing makes PREMIUS digital 3 Chip impervious toambient light conditions. Sunlight or fluorescent overhead lightsthat cause false defects on analog systems, have no impactwhat-so-ever.3

Standard FeaturesIntuitive GUI With Touch Screen OperationCombine all this advanced technology witha unique graphic user interface (GUI) and youhave an extremely intuitive and functionalpressroom tool.• Touch screen operator interface respondsinstantly to operator commands• Single media GUI is more efficient thansystems with cumbersome combinationsof pull down menus, icons and a mouse.Operators spend less time running thesystem and more time printing• Neatly organized “task” icons, colorcoded by function, makes it easy to learn• Multilingual OSD (On-Screen Display)• Password protected system settings• Information window provides real time data• Alarm status indicator on the GUI“Smart” Visual CapabilitiesPREMIUS digital 3 Chip has the most comprehensive package of“smart” visual inspection capabilities of any system on the market.• Positional Memory with Image Gallery• Area of interest (AOI) with Auto Image Centering• Quick Zoom Function• Split Screen Reference Images• Auto Scan for the Entire Print Repeat• Job Save MemoryImage Stabilization SoftwarePREMIUS digital 3 Chip was designed for use with a wide range ofsubstrates, from heavy weight paper to extensible films as light as1/2 mil PE. The product has three levels of protection engineeredinto the software that work diligently in the background. Thesehighly sophisticated algorithms automatically compensate forimage drift caused by web movement, stretch and snap backcaused by tension variation and other web movement anomalies.TMPlaces an electronic magnifying glass over the live image, whichcan be moved just as you would a loupe on the web.The new Electronic Loupe provides 2 times electronicalmagnification on top of the 16 times optical zoom lens.PREMIUS digital 3 Chip uses a unique Virtual Repeat Technologypioneered by BST. The operator can easily navigate about theentire print repeat at the touch of a button.• Complete thumb-nail overview of the entire print repeat• Fast and natural image navigation – simply touch any thumbnailand the camera instantly moves to that area and displays the liveprint.An Expandable Platform That Can Grow As You Grow!PREMIUS digital 3 Chip is by design an expandable platform that cangrow and change with your business.As your needs change, so can your print management system.Add defect detection, color monitoring, barcode check, registerpresetting or front-to-back image overlay as the need arises andyour budget allows.4

Standard FeaturesSuperior 3 Chip Digital Camera TechnologyThe high resolution 4.2 mega pixel 3 chip camera sets newstandards of performance and accuracy throughout the system.Featuring a horizontal resolution of 3 x 1,360 lines and a verticalresolution of 3 x 1,024 lines this technology provides imageresolution three times greater than comparable competitivesystems. It’s the first thing you notice. Detail that is crisp.Color that is rich and saturated. Contrast that is discernable.Hues that are the same on the monitor as on the printed web.Picture quality that is photographic in every respect.Multiple Fields of View (FOV)The following three fields of view are now available:• MEDIUM (M-FOV): 220 mm x 160 mm (9“ x 7“)• LARGE (L-FOV): 330 mm x 240 mm (13“ x 9“)• EXTRA LARGE (XL-FOV): 440 mm x 330 mm (17.5“ x 13“)Our new 440 mm x 330 mm (17.5“ x 13“) extra large field-of-viewis four times larger than usual.Defect detection using this option will be performed 4 times faster,and will inspect 4 times as much material.Image Resolution Comparable To Print ResolutionPREMIUS digital 3 Chip represents the first inspection system everto offer effective resolution that is comperable to the resolution ofhigh quality printed products. Typically this is done today atresolutions of 40-70 L/cm (100-175 dpi). Using the 220 x 160 mm(9” x 7”) field of view provides an effective camera resolution of60 L/cm (155 dpi).MEDIUM (M-FOV): 220 mm x 160 mm (9“ x 7“)1:1 DisplayBy using the XL-FOV the 4.2 mega pixel resolution makes thedream of every printer – display of the print repeat on a scale of1:1 – finally come true.For the first time ever, print from the web can be displayed to theoperator at full size and with sufficient resolution to see detail andcolor just as they would with the naked eye. Operators will for thefirst time ever, be able to look at the printed web at full sizewithout having to stop the press.LARGE (L-FOV): 330 mm x 240 mm (13“ x 9“)4 Times Faster Defect Detection,400% Greater Sampling RatiosDefect detection on the entire repeat can now be performed4 times faster than before. The amount of material inspected(sampling ratio) is also 4 times greater.On a web width of 1.2 meters (60"), with an 800 mm (32”)repeat, using the extra large field of view, the entire print area willbe inspected by just 9 pictures.Defects are found and corrected far more quickly, resulting in lesswaste and greater productivity from the press.EXTRA LARGE (XL-FOV): 440 mm x 330 mm (17.5“ x 13“)More Accurate Defect DetectionEven the smallest print defects hardly noticeable to the nakedeye can be recognized with ease. Process management functionssuch as defect detection and color monitoring are more powerful,capable and reliable than ever before; and find defects othersystems do not.5

Intelligent Software OptionsTo Maximize Press ProductivityDefect DetectionAn Effective Tool To ManagePrint Quality And Reduce WastePREMIUS digital 3 Chip utilizes powerful algorithms which allow it toautomatically detect a variety of common print defects such asstreaks, hickeys, splash, voids, mis-register, missing type and fill-in.Print quality can be effectively managed throughout the run,resulting in reduced waste and happier customers.The overall impact can often generate payback in months.Color MonitoringConsistent Color Roll-To-RollAnd Job-To-JobThe Color Monitoring option performs automatic inlinecomparison of the live color with previously stored standardvalues at user-defined positions on the web.When actual print color approaches the set outside tolerance,an alarm alerts the operator and shows where the developingcolor problem is located on the web. The operator has time to takecorrective action before actual color reaches an unacceptable level.The result is consistent color from roll-to-roll and job-to-job.Barcode CheckInline Barcode Quality InspectionRegister PresettingTime Is MoneyOn press, bar code quality can change dramatically in a very shortperiod of time.For example: just a slight change in impression can cause a perfectlyacceptable bar code to be rendered unreadable in seconds.Unless bar codes are being continuously monitored on press, thisoccurs without the operators’ knowledge.One of the most effective ways to improve CI press productivityis to reduce the time required for make-ready. By incorporatingthis technology, the process of bringing a new job into correctregistration can be accomplished in less than a minute.The “single step” correction method used brings jobs into registerfaster than competitive systems.Please take detailed information about the software options from the corresponding separate leaflet sheets.Job & Roll ReportingAn Important Part Of Your TQM SystemGenerating comprehensive reports on the quality of print from apress is as simple as connecting a printer to the PREMIUS digital 3 Chipand pressing an icon. The reporting function automatically generates joband roll reports, provides a comprehensive statistical analysis of thejob and a detailed statistical and informational analysis of each rollthat comprised the job.The report begins with an “Overview” section, showing when thejob was run, start and stop time for each roll in the run and thelength of each roll. The report shows the critical system settingsduring the run, i.e. warning and alarm thresholds, color space used,defect sensitivity settings etc.. The “Overview” also providesdetailed information on each quality attribute inspected during therun - color, defects and bar codes.Following the overall job report are individual reports for each rollthat made up the job. The roll reports contain great detail on qualityparameters and on every specific “event” that occurred as the jobwas produced.8Sample of the PREMIUS digital 3 Chip job report

Hardware OptionsDual Camera SystemDuplex Printing Made Easy.With an optional second camera,PREMIUS digital 3 Chip becomes a veryeffective tool for simultaneous inspectionof both the front and back side of a web.The package includes two different modesfor inspecting the print:• Front and Back (FaB)Camera 1 and camera 2 operateindependently from each another andcan be positioned in any suitable positions.• Front to Back (FtB)Movement of both cameras is synchronized,i.e. the back camera automatically followsthe movement of the front camera.Front and back side displayFront to back displayDual System Module (Option)By also adding the Dual System Moduleand a second monitor the system can beused to inspect front and back side of theweb, on two independent monitors.Each monitor displays a live image fromone camera, as if you had two inspectionsystems.Live image front side camera(viewing monitor 1)Live image back side camera(viewing monitor 2)The optional back strobe serves to checkfront-to-back register accuracy at manydifferent substrates.Back Strobe AssemblyA back strobe assembly is used to visuallycheck the front-to-back print register (FTBR)of translucent and many other substratesby illuminating the web from the oppositeside.Mounted opposite the camera, the imageon the monitor will show the front sideprinting with the backside printing shiningthrough.Strobe Options For UV,Coatings Or LacquersBecause some applications require specialimage illumination, PREMIUS digital 3 Chipoffers a variety of supplemental strobeoptions - UV strobes (for viewing of UVfluorescent materials) or reflective strobesto view lacquer or coatings more easily.Installation adds another dimension ofoperator functionality to your system.Second Viewing Monitor (Option)The optional second viewing monitor is themost cost effective hardware option weoffer. Having the ability to monitor thesystem from multiple locations, meansfaster response to print problems, evenlower waste from the press, improvedoperator functionality and maximum useof the power of PREMIUS digital 3 Chip .• Inspect print quality from multiple locations• Operators can more easily monitor thesystem without having to be at the console• Faster response to and correction ofidentified print, color or bar code defects• Dual camera systems can havesimultaneous display of both cameraimages in full screen mode(only in conjunction with the DualSystem Module).• Big monitors with a diagonal of 40“ andmore can be connected parallel to thestandard 19“ TFT.9

After The Sale Service And SupportWith over 15,000 video inspection systems and 60,000 web guiding systems installed,BST International is known worldwide for quality and reliability in every detail.We work very hard to insure that every product we make is meticulously engineered toprovide years of reliable operation. But we believe that to be successful also requires astringent network of after the sale service and support. BST International and our subsidiarycompanies all over the world are dedicated to providing our customers with the verybest in every respect.Start-UpBST service technicians are trained on theproper system installation on all currenttypes of printing presses. They work hardto see that downtime during the start-upprocess is kept to an absolute minimumand that your system will operate properlyfor years to come.TrainingOur experienced technicians train youroperators on how to usePREMIUS digital 3 Chip to its full potential, sothat your investment in technology isquickly rewarded with reduced waste andimproved press productivity.Hotline ServiceOur hotline service provides competenttechnical advice for all questionsconcerning your system.Worldwide Support Is Just A Phone Call AwayNo matter where you are in the world, our optional Remote Maintenance Serviceguarantees a fast and economical solution.Experienced system specialists are waiting in our head-office in Bielefeld to ensure that yourinspection system is running trouble-free. All you need to do is provide an analog phoneline to the PREMIUS digital 3 Chip operating desk.Once logged into your system, our specialists can diagnose and trouble shoot problems,perform routine maintenance, install software upgrades and even identify operator error.Most problems can be effectively solved online.The PREMIUS digital 3 Chip Remote Maintenance means• Faster diagnosis and repair of problems• Minimal down time• Eliminate the need for on-site service calls• An effective way to perform routine maintenance• Online installation of software updates• Purchase and installation of new software programsAsk your local representative for a quote on adding the Remote Maintenance Package toyour system.BST ServicePREMIUS digital 3 ChipTelephoneConnectionRemote service via PREMIUS digital 3 Chip Remote Maintenance10

Technical SpecificationsTechnical DataCamera:Type:3 Chip DigitalProgressive ScanResolution: 1380 x 1024 x 3(4.2 mega pixel)FOV: M: 220 x 160 mm (9” x 7”)(see drawing A)L: 330 x 240 mm (13” x 9”)(see drawing B)XL: 440 x 330 mm (17.5” x 13”)(drawing on request)Zoom Ratio: 32 (16x optical, 2x digital)Power Supply:90 V –132 V, 50/60 Hz, 400 VA198 V –264 V, 50/60 Hz, 400 VAUninterruptable Power Supply (UPS)115 V/ 230 V +10% -15%,50/60 Hz, 750 VAModemInternal 56K fast modem forremote supportAmbient Operating Temperaturemin 0 degrees ( 32 degrees F)max 40 degrees (104 degrees F)Monitor see separate specificationStorage Temperature-10 to + 55 degrees C14 to +131 degrees FHumidity20 – 80% non-condensingDimension SheetsWW = web widthTL = traverse lengthDrawing A (No. 0081390.000.50), Traverse assembly, M-FOV, 220 mm x 160 mm (9“ x 7“)Drawing B (No. 0081388.000.50), Traverse assembly, L-FOV, 330 mm x 240 mm (13“ x 9“)11

BST – A WorldwidePresenceBST production linesWeb Guiding SystemsA wide product range of individualcomponents up to the most sophisticatedcomplete system solutions guaranteesan optimum adaptation to all kinds ofindustrial applications.BST in the EMG GroupPro MarkJapanWeb Inspection SystemsColor video systems for manual andfully-automatic operation; adaptedto the individual requirements on site.SayonaLatinaPrint Process ManagementFully automatic image inspection,color monitoring, bar code verificationand defect detection for web-fed printingand converting machines.FranceItaliaRegister ControlColor register measuring systems forautomatic register pre-setting on FlexoCI presses and color register and cutregister controls for web offset presses.Ink ControlDigital ink ducts remote controlsfor web offset presses.AutomationSystem solutions for process optimizationby individual advice and creation ofcustomized software.Web CleaningCleaning system removes dry unattachedcontamination. Simultaneous cleaningof both sides of the web with minimumspace requirements.The BST Group with office and productionfacilities in Bielefeld, has been a leadingmanufacturer of quality assurance andquality inspection systems for many years,supplied to the web converting andprocessing industries.More than 250 staff members worldwideare dedicated to maintain the highreputation for quality and efficiency,which is proved by over 60.000installations in 70 countries.BST International GmbHHeidsieker Heide 53D-33739 Bielefeld, GermanyPhone: +49 (0) 52 06/999-0Telefax: +49 (0) 52 06/999-999Web Site: www.bst-international.come-mail: info@bst-international.comBST Pro Mark650 West Grand Avenue # 301Elmhurst, Illinois 60126 USAPhone: (630) 833-9900Telefax: (630) 833-9909Web Site: www.bstpromark.comLocal representative© BST International GmbH, Bielefeld, Germany • BST 161/0305 en • Subject to change