Document Integrity and Beyond!

Getting the job done on time is one thing, but getting the job done right is quite another. Today’s unique print environment requires shorter runs, more changeovers, and higher levels of personalization in order to remain profitable. And, with these demands comes a greater chance for error. The typical quality control protocols for document finishing such as double detection, jam detection, and operator attention to detail may have once been sufficient for static, long-run print jobs, but no longer provide the necessary level of security – and never offered any kind of audit trail or tracking. In light of recent legislation, the need is even more urgent. Privacy protection laws require that the processing of any items containing personal data, especially when combined with financial and health information, must be documented as far as their assembly and final routing.

Fortunately, new technology has surfaced to address the growing need for in-line verification, inspection, and integrity analysis. One example is Standard’s VIVA technology, which is an automated, camera-based integrity and inspection system used on Standard Horizon bookletmakers, saddlestitchers, perfect binders, and folders as well as Standard KAS envelope inserters. With benefits reaching far beyond simple inspection, VIVA is the most complete and state-of-the-art complement to any document finishing environment, providing quality control, tracking, end-to-end system control and reporting for personalized document production.

Using VIVA technology, companies can comply with new requirements to ensure that pieces are properly printed and put together – particularly where sensitive, confidential, and personal data are involved. The software can also ensure that every non-sensitive piece has been correctly printed and assembled – reducing waste and guaranteeing accuracy for all work completed in the bindery. For example, in the perfect binding area, the system can verify proper signature order at the stacking section, book block and cover matching on the perfect binder, and perform a final check at the trimmer. Any mistakes in book production can be costly, so job tracking is critical to prevent expensive reprints and to trigger a reprint should the need arise. The software can also perform sheet and set-level integrity checking during booklet production or verify the order of signatures in the folding process. VIVA will stop production immediately on static work if sheet or cover replenishment was done improperly, verifiable print areas are missing, or other common operational errors are identified. Additionally, VIVA supports virtually any symbology (OCR, OMR, and most 1D and 2D barcodes) for complete flexibility.

The growth of digital color print has also sparked the development of camera-based web inspection technologies which capture high resolution images of the full web width to verify integrity of each page on a printed roll. The Standard Hunkeler WI6 offers full quality inspection in monochrome or color in both simplex and duplex versions for up to 22" web feed systems. (The WI7 version provides identical technologies for web widths up to 40".) These systems provide continuous digital print quality assurance to customers for mass mailing, print on demand, and variable data applications. Print and integrity problems are immediately detected so incorrect documents can be automatically diverted and instantly reprinted to guarantee error-free output, minimize waste, and reduce downtime. The system can perform up to fifty different checks on print quality such as the detection of ink spills or blank streaks, verification of barcodes or postal codes, and image quality inspection.

In a world of “better, faster, smarter”, these new technologies are helping printers expand their capabilities and remain competitive. In booth 1902, Standard will be demonstrating its VIVA suite of inspection systems on several products, including perfect binders, saddlestitchers, and sheet feeders, and its Hunkeler WI6 Web Inspection product on a roll-to-fold line with dynamic perfing on a direct mail piece.