iPQ-Center

The iPQ-Center from BST eltromat International is a modular solution for complete quality assurance in flexo and gravure printing, as well as other printing processes. Its backbone consists of the iPQ-Workflow, which integrates the three quality assurance systems – iPQ-Check for 100% print inspection, iPQ-View for video web inspection, and iPQ-Spectral for inline spectral color measurement – in a closed quality assurance process. This, in turn, creates the basis for continuous optimization of printing processes. BST eltromat pursues an all-inclusive approach to print production by integrating production-assisting, third-party software tools in its workflow, also including prepress operations.

The four modules of the iPQ-Center cover virtually the entire range of demands on quality assurance in printing processes. The three quality assurance systems, iPQ-Check, iPQ-View and iPQ-Spectral, each assume different quality assurance tasks. Each system can be used as a stand-alone solution. In practice, however, two or all three of the systems are usually integrated into all-inclusive solutions for quality assurance and configured for the specific customer.

The fourth module, iPQ-Workflow, seamlessly interconnects these three systems to create a closed quality assurance process with a uniform, convenient operating concept. The user interface provides a clearly arranged display of all interactive setup and operating menus, along with all inspection results – including live images from the printing press – on a multi-touch monitor, in which context intuitive operation with gesture control offers the machine operators maximum convenience.

Thanks to the modular structure, printers can integrate the individual modules into their processes successively. For instance, many customers start with the iPQ-View video web inspection module, subsequently adding the other modules in line with the development of their demands – step by step, all the way to a complete iPQ-Center. Any desired combination is possible, meaning that customers who begin with just one module can be absolutely certain that they are making a safe investment. All the systems of the iPQ-Center are available as entry-level Eco versions or Pro versions for higher demands.

iPQ stands for "increasing Productivity & Quality" in relation to the printing process. The iPQ-Center reliably detects and logs defects occurring during printing. Printers can reliably eject defective products, meaning that print products cannot get to customers if they do not comply with their quality standards. In addition, the machine operators can intervene in the process and correct settings, quickly and at an early stage. In this way, they can ensure that the specified printing tolerances are met on the press, and that waste is avoided or minimized from the outset. That can be of decisive importance for profitability, particularly in the case of jobs with small margins. Moreover, the real-time data collected during production, and the defect logs, form a sound basis for continuous, long-term process improvement – after all, this information permits reliable conclusions to be drawn as to where parameters are going astray in print production.

Top quality is not necessary for all print jobs. The iPQ-Center supplies print providers with all the data they need for targeted fine-tuning of their printing process. For example, they can run their presses at higher speeds for certain jobs, because the quality then produced still meets the customers' demands – as they can moreover reliably monitor and ensure with the help of the iPQ-Center. In other words: the iPQ-Center can be used for targeted improvement of productivity and profitability in general.

Different solutions for different quality assurance tasks

iPQ-Check is the name of the module for 100% print inspection at web widths of up to 2,800 mm and machine speeds of up to 1,000 m/min. High-performance line scan cameras deliver detailed color image data across the entire print format, and log the production results from the first revolution of the impression cylinders. Mature technologies and algorithms guarantee complete, reliable control, so that sources of defects can quickly be located and eliminated. iPQ-Check distinguishes between process-related and sporadic errors in this context. The iPQ-Check lighting is a unique feature, specifically for opaque materials. In addition to direct lighting, there is also diffuse lighting for highly reflective materials, which again guarantees outstanding inspection results.

iPQ-View is a powerful tool that offers a wide variety of standard functions and optional features for video web inspection, including simple error diagnosis in the printing process. iPQ-View displays live images of the printing process in excellent quality, on the basis of which the machine operators can visually assess the print quality and influence it within very short response times. The key features are the high-resolution digital cameras, various optical zoom functions for adapting the field of view without any loss of display quality, and the diverse lighting options that ensure uniform, optimum illumination of the printing area on all common materials. Particularly convenient is the monitor's split-screen function, which allows the machine operators to compare live images from the production process, either with reference images or with live images from a second camera. The operators can choose whether to split the screen horizontally or vertically, or whether they prefer a picture-in-picture display. These features are completed by supporting functions, e.g. for barcode verification, or Haze Guard for detecting printing errors with low contrast, such as scumming.

iPQ-Spectral for inline spectral color measurement enables printers to conveniently comply with given color standards. The system was developed in cooperation with X-Rite and guarantees the comparability of data measured offline and inline via the XRGA standard. iPQ-Spectral performs real-time, inline measurement of the color data with a high-resolution spectrophotometer on the press, comparing them with given reference values. If the system detects deviations, it displays them in the form of informative statistics, diagrams and images. The machine operators can see at a glance where they need to intervene in the process in order to avoid waste. Measuring within the press means that color images are captured permanently throughout the entire print job – a decisive advantage in comparison with hand-held measuring instruments, which usually only permit a few measurements per print job. In practice, it is common only to carry out measurements at the start of a new reel. However, information on the quality of the color over the entire reel is then not available. Important data of iPQ-Spectral include the spectral measuring range from 380 to 730 nm and the maximum measuring frequency of 30 measurements per second. The measuring field can have a minimum size of 5 x 5 mm and be positioned at any desired point within the printed image. iPQ-Spectral measures both solid and half-tone colors.

iPQ-Workflow for even more convenience and capabilities in quality assurance

The Workflow module completes the capabilities of the iPQ-Center with additional functions. This increases convenience in quality assurance, and production reliability. The iPQ-Workflow moreover offers further options for avoiding or minimizing waste. Unique on the market, the PDF Plate Auditor, for example, already raises the alarm during the proofing phase, if damaged or incorrect forms are mounted on the presses. The PDF Plate Auditor compares the current printed images with the reference images from the pre-press stage. Right at the start of setup, for instance, it detects the mounting of printing forms in the wrong language when producing country-specific packagings.

The Event Logger provides lane-based logging of all relevant defects. It records the defect classes and the running-meter positions, as well as the images of the defects and the associated reference images. The same applies to other process-relevant information, such as changes in the inspection sensitivities. The appearance of the PDF Reports can be given a customer-specific design with the help of the Report Generator.

Not every deviation in the printing process automatically means waste. The Quality Assistant allows the machine operators to individually assess defects detected by the system to decide whether they really are relevant. The Waste Indicator offers convenient options for marking defects in material webs during printing, initiating ejection of the material, or reporting waste in some other way. The Rewind Navigator guarantees convenience and high productivity when eliminating defective areas on the rewinder.

A decisive attribute of the iPQ-Workflow is its openness to production-assisting solutions from other manufacturers. The inspection systems of the iPQ-Center have for some time already featured interfaces to Color Cert, AxonGraphix, PantoneLIVE or Colorware PressView, among others. A new addition is the bidirectional interface to the Automation Engine from ESKO, which, among other things, gives flexo and gravure printers new possibilities for further reducing setup times. For example, targets for the individual modules of the iPQ-Center can be set conveniently with the Automation Engine. Moreover, an interface designed specially for the purpose brings the iPQ-Center closer to the prepress and press stages. Further integration tasks are on the way – such as combination with ERP solutions.