Luster – The inspection solution for almost all materials in production! The system with the 100% quality inspection convinces with different modules to meet all needs.
Whether variable codes, barcodes, different materials, such as opaque or holographic – the versatile equipment allows you to control and analyze your production in- and offline to prevent errors in production, reduce material waste and keep the work flow constantly stable.
Label inspection with Luster
The LabelRoll series is specifically designed for quality inspection of labels and narrow web applications such as beauty product labels, food labels, beverage labels, wine and premium beverage labels, pharmaceutical labels and other labels.
Through easy integration into the printing workflow, the LabelRoll series not only helps customers reduce production costs, but also improves production efficiency and quality management levels, resulting in increased profit and competitiveness.
| Solution | used model |
|---|---|
| Printer: Inline inspection | LabelMaster-P inspection system |
| Slitter Rewinder: Offline inspection and automatic control, as well as stop at errors | LabelMaster-F inspection system |
| Workflow-solution: Inline inspection and Rewinder/Doctor Machine | LabelMaster inspection system, central Server, Data Viewer Software and Rewinder/Doctor Machine |
Examples for error detection:
Inline-inspection-workflow:
- Installed on the press to effectively control the print quality, avoid high loss of consumables, thus saving production costs and ensuring color consistency
- Real-time light and sound alarm, also visual alarm
- High-speed performance and accurate inspection performance to increase production efficiency and reduce user dependence
Offline-inspection-workflow:
- Mainly installed on the rewinder for a final quality check before delivery
- system controls the rewinder and automatically stops at the fault position to remove or replace the faulty label.
- Operator can also control and skip the errors that do not need to be stopped to increase work efficiency
Inline-inspection and Doctor Machine worflow:
- is installed on the press to monitor the print quality, avoid unnecessary consumption of materials and automatically send incorrect data to the central server for readout and processing
- Rewinder/Doctor machine automatically loads defect data and stops at critical defect positions for removal and replacement.
⇒ By separating inspection and troubleshooting, this workflow solution can significantly improve your work efficiency
PrintingPlus quality inspection software:
- Scientific quality standard: A new software algorithm enables a reliable and strong inspection performance. No learning or reading of different products. This increases the reliability of the inspection and prevents false alarms.
High inspection accuracy: A 100% inspection performance is actually achieved by the PrintingPlus 6.0 software reliably detects every small error, such as a colon or decimal point in text. - Exact classification of errors: The PrintingPlus 6.0 software identifies and categorizes different types of errors with great precision. The operator can use different quality standards depending on defect type and area to prevent false alarms and achieve the best possible inspection performance.
- Ease of use: PrintingPlus 6.0 is very easy to use, requiring little computer knowledge. few computer skills
is required. A few steps on the screen are enough to complete the setup in a few minutes. Enable clear instructions in the tolerance settings the user a quick setup of the job. - Faster than any system you have ever seen: The software requires only one computer to achieve the speed and performance of 4-6 computers. Due to the advanced algorithm, the system is able to perform high-speed inspections with sustained high accuracy.
Optional modules:
CodeHERO:
- Suitable verification and inspection of barcode, 2D code, sequence numbers, OCR and other variable file types
- Achieves a decoding speed of up to 400 codes per second
- Automatic extraction of variable data, if the quality standard is given
ColorHERO:
- Monitoring of up to 20 color patches simultaneously
- Monitoring with color curve and real-time alarm
Finds color deviations in Δ E>2 - Support of different Delta E calculation methods and thresholds for a perfect result
ProofHERO:
- Different images can be combined into one proof
- Supports various file formats: PDF, JPEG, TIFF, BMP
- Supports the use of different PDF layers
- Compatible Offline Printing Proof System
- Automatic Exposure Calibration
GradingHERO:
- Special alarm and handling process for serious or continuously occurring quality problems to avoid man-made errors
- Intelligent and precise defect classification
- Every error can be tracked
- Analysis of defects and sending a quality report to ensure production and production management
Mainfeatures:
Inline quality inspection with the LabelMaster-P series:
The Label Master-P Series inline quality control system is installed on presses such as flexographic, letterpress and digital presses to control print quality on all narrow webs and labels to reduce waste and production costs and increase efficiency. The system is able to detect errors such as incomplete/missing print, dirt stains, ink stains, misregistrations, color variations, improper stamping and punching, variable data, etc. The optical system is integrated in a box, with camera and light source easily changed to meet the inspection requirements of different materials.
Excellent optical system:
The adaptive optical design and illumination enables the LUSTER system to reliably detect all types of defects on different substrates, including highly reflective, transparent, clear and opaque materials. Compact and modular design for different integration requirements and easy maintenance.
Easy handling:
You only need one master image as a reference for the required job setup, no learning or training process over multiple images to achieve the best and most accurate results. Setting up PDF proof reference jobs is also supported. Automatic recognition, calibration, extraction and positioning, as well as other automatic functions, are included to significantly reduce setup time for a quick start. A wizard and the intuitive user interface
enable the operator to understand and operate the system easily.
Quality report and analysis for production improvement:
After each inspection, a quality report can be generated with detailed statistical inspection analysis, defect images and positions, and other results to provide clues for future improvements. Defect data is stored for up to 6 months to allow the customer to track quality issues at any time.
“All in One” quality control:
The system not only provides alarm and real-time error control. It also has a live web monitoring function, for monitoring print quality with pixel-level zoom to save the cost of additional investment and improve inspection results
Technical specifications:
| Model | LabelMaster-P |
|---|---|
| Fields of application | All types of labels and stickers, for pharmaceutical, drugstore, food and beverage packaging, as well as a variety of other applications |
| Materials | Opaque, transparent, reflective, clear-on-clear |
| Error type | Known defects: Stains due to dirt, color or flaws, lack of register, inaccurate die-cutting, color deviations, dust and more …
3D defects (optional): bubbles, scratches, glue residues, finishing defects and more |
| Width | 330 mm / 420 mm / 520 mm |
| max. Speed | 200 m/min / 200 m/min / 200 m/min |
| Camera options | Standard 4K resolution, 8K resolution color line scan camera, 4K/8K resolution mono line scan camera |
| min. Error correction (4K) | 0.04 mm² / 0.05 mm² / 0.07 mm² |
| Register deviation | 0.01 mm / 0.01 mm / 0.01 mm |
| Other modules |
|
Quality inspection with the LabelMaster-F series:
With the latest PrintingPlus 6.0 software and hardware design, the user is offered a whole new inspection experience. The well thought-out design makes it possible to install the machine on any platform. At up to 300 m/min, the inspection is efficiently optimized while maintaining its 100% quality inspection of common and small defects as well as 3D defects. The various optional upgrades allow, among other things, variable data to be checked, color deviations to be corrected very accurately, a printing proof to be produced and clear-on-clear and highly reflective material to be checked to meet all requirements. Luster also offers an integrated slitting rewinder, which as an all-in-one platform provides better performance and customer support.
Mainfeatures:
Strong inspection performance:
100% quality inspection of common, even very small defects, as well as 3D defects, such as varnishing and lamination defects. The machine can also inspect clear-on-clear labels, holographic material and highly reflective material.
Easy to use:
Only a master image is required for setup.
The inspection can start right at the first meter. Automatic setup functions during setup allow the operator to learn quickly and easily. All previous jobs are saved and can be reused with one click.
Easy to change optical system:
The unique “Drawer” design allows the user to easily and quickly switch between different light sources and cameras to inspect differentiated products and substrates.
More integrated functions:
In addition to checking for known defects, there are functions such as defect classification, color management, inspection of variable data, PDF proof job reference and much more. .
Technical specifications:
| Model | LabelMaster-F |
|---|---|
| Fields of application | All types of labels and stickers, for pharmaceutical, drugstore, food and beverage packaging, and a variety of other applications |
| Materials | Opaque, transparent, reflective, clear-on-clear |
| Error type | Common faults: Stains due to dirt, color or flaws, lack of register, inaccurate die-cutting, color deviations, dust and more …
3D defects (optional): bubbles, scratches, leaked glue, paint defects, … |
| Width | 330 mm / 420 mm / 520 mm |
| max. Speed | 200 m/min / 200 m/min / 200 m/min |
| Camera options | Standard 4K resolution, 8K resolution color line scan camera, 4K/8K resolution mono line scan camera |
| min. Error correction(4K) | 0.03 mm² / 0.05 mm² / 0.07 mm² |
| Register deviation | 0.1 mm / 0.1 mm / 0.1 mm |
| variable data types (optional) | 1D-Codes: CODE128, CODE39, CODE93, EAN8, EAN13, UPCA, UPCE, ITF, CODABAR 2D-Codes: QR, DM, PDF 417 SN-Codes: SN Codes, which contain numbers and capital letters Sequence inspection: sequence errors, repetitive numbers, wrong numbers |
| Specifications of the mechanical platform (330 mm): | |
| Thickness | 40 µm ~ 500 µm |
| Width | 40 mm ~ 330 mm |
| max. Working-Speed | 200 m/min |
| max. Unwinding diameter | Ø 700 mm |
| max. Rewinding diameter | Ø 700 mm (two rolls) |
| Web Guider | two |
| Rewind Accuracy | ± 0.2 mm |
| Slitting | Standard (10 knifes) |
| Axis size | Ø 76 mm |
| Calculation-Sensor | Standard: one photoelectric counter Optional: an ultrasonic meter |
| Error Stop Accuracy | ± 20 mm |
| Voltage range | 0N-10N |
| Air supply | 0.4 MPa ~ 0.6 MPa clean compressed air |
| Dimensions | 2.800 mm (L) x 1205 mm (B) x 1460 mm (H) |
| Weight | ~ 1.7 t |
Technical specifications:
| Specifications of the mechanical platform (330 mm) | |
|---|---|
| Material thickness | 100 µm ~ 300 µm |
| Material width | 40 mm ~ 330 mm |
| Speed | 200 m/min (rewinding); 60 m/min (curved cut) |
| max. Unwinding diameter | Ø 800 mm |
| max. Rewinding diameter | Ø 800 mm |
| Length of sheet cuts | 100 mm ~ 450 mm |
| Stacking height | 100 mm |
| Air supply | 0.4 MPa ~ 0.6 MPaclean compressed air |
| Dimensions | 5.815 mm (L) x 1.200 mm (B) x 1.500 mm (H) |
| Weight | ~ 1.8 t |
LabelRoll-RS Series Roll-To-Sheet Offline Quality Inspection:
The LabelRoll-RS has the same functions as the LabelRoll-F, but has an additional sheeting unit. It combines the functions of inspecting and cutting, ejecting defective sheets and stacking good sheets.
LabelRoll-LT series for offline quality inspection:
The LabelRoll-LT series was specially developed to perform print quality inspection on labels that are highly sensitive to web tension, such as electronic labels, textile labels or irregularly die-cut labels. The innovative hardware and design allows to simulate a manual rewind to rewind labels with low tension, not damaging the label corners and also preventing problems with glue leakage.
Mainfeatures:
Strong inspection performance:
In order to achieve extraordinary inspection results, defects with a size of at least 0.03 mm² are detected. This results in fewer false alarms, especially for errors such as broken letters, etc. Optionally, the CodeHero module is available to inspect and verify barcodes and 2D codes. A 3D inspection is also available as an option to detect defects such as bubbles, wrinkles, scratches or contamination by adhesives.
Control for low web tension:
Innovative hardware and design allow to simulate a manual rewind and thus to rewind labels with low tension and even winding. Among other things, this avoids problems with glue leaking during inspection.
Easy handling:
Quick and easy job setup. Support of differentiated settings for different error types and different areas of the label. The job settings of the job can be saved by the operator and reused with one click. To inspect the same products with different appearance, all that is needed is a mouse click on the reference image and the job can be started.
Technical specifications:
| Model | LabelRoll-LT |
|---|---|
| Applications | Electronic labels, textile labels, labels with irregular die cut and other types of labels that are highly sensitive to web tension |
| Materials | Opaque, transparent, reflektive, clear-on-clear |
| Error type | Common faults: Stains due to dirt, color or flaws, lack of register, inaccurate die-cutting, color deviations, dust and more …
3D defects (optional): bubbles, scratches, leaked glue, paint defects, … |
| Variable data (optional) | 1D-Codes: CODE128, CODE39, CODE93, EAN8, EAN13, UPCA, UPCE, ITF, CODABAR 2D- Codes: QR, DM, PDF 417 SN-Codes: SN Codes, which contain numbers and capital letters Sequence inspection: sequence errors, repetitive numbers, wrong numbers |
| Width | 20 mm – 330 mm |
| Speed | 60 m/min – 80 m/min |
| Specifications of the mechanical platform (330 mm) | |
| max. Width | 20 mm – 330 mm |
| max. Speed | Manuell: 40 m/min; Automatic: 60 m/min |
| max. Unwinding diameter | Ø 450 mm |
| max. Rewinding diameter | Ø 450 mm |
| Web Guider | one |
| Rewind Accuracy | ± 0.35 mm |
| Rewinding/unwinding size | Unwinding: Ø 75 mm Ventilation shaft; Rewinding: Ø 75 mm sliding shaft |
| Error Stop Accuracy | ± 20 mm |
| Air supply | 0.4 MPa ~ 0.6 MPa clean compressed air |
| Dimensions | 2.200 mm (L) x 1.200 mm (B) x 1.350 mm (H) |
| Weigth | ~ 0.8 t |