Consumables

Continuous quality control reduces production costs for printed corrugated board

Thursday 27. August 2020 - DS Smith ensures print quality at its Mannheim production plant with the 100% inline inspection system CartonSTAR from ISRA VISION, a world leader in surface inspection systems. The system reliably and reliably distinguishes quality-relevant printing errors from inhomogeneous structures on the corrugated board surface.

In addition, the continuous quality and process control of the printed image continuously reduces production costs and ensures the sustainable use of resources.
Printed corrugated board is playing an increasingly important role as a packaging material. This is not least due to the increasing mail order business, which relies on the almost alternative packaging made of corrugated board. The rapid growth of the industry is closely linked to this reliable packaging material.
DS Smith is one of the world’s leading suppliers of corrugated board packaging. The company is headquartered in London and focuses on the development and production of sustainable packaging solutions in 37 countries. In Germany and Switzerland it employs over 2,900 people at 21 locations. At its production plant in Mannheim DS Smith uses the newly installed Mitsubishi EVOL100 production line to manufacture various types of cartons and trays for food, technical products and hygiene articles, which are printed using the flexo process.
In compliance with the company’s internal standards, a print image monitoring system was required. The installation of an inspection system is practically an industry standard and therefore an absolute necessity. Due to the positive experience of colleagues from the sister plant in Arnstadt, those responsible at DS Smith’s Packaging Division became aware of ISRA.
The CartonSTAR inspection system enjoys a very high level of acceptance among the machine operators in Mannheim. A two-camera solution with backline high-performance LED lighting is used. Especially the users directly at the press benefit from the system, as the risk of misprints is considerably minimised due to the complete control of the printed images.
The 100 % control of the print image significantly reduces the number of complaints, although the demands of the user’s customers are constantly increasing. Even individual defective sheets with errors in the printed image are reliably detected and rejected before further processing. The system is able to “ignore” the inhomogeneous surface structure of the corrugated board and still reliably identify all quality-relevant faults – even at the highest speeds of 18,000 sheets per hour. All defects are precisely classified. Says production manager Daniel Malolepszy: “This special feature of the CartonSTAR system enables relevant and non-relevant defects to be separated, thus making a decisive contribution to the system’s commercial success”. In particular, the fact that the classification can be carried out quickly and easily on a customer-specific basis significantly increases the productivity of the printing process. The advantages of using the inspection system can thus be clearly measured in terms of improved productivity and reduced complaint costs.
The inspection system also documents all incidents and thus enables verifiable quality management. With the inspection during the printing process DS Smith ensures a continuous feedback regarding print image and material quality. For the user, CartonSTAR represents an “absolutely well thought-out system”. Added to this is the good experience with ISRA’s service personnel. With the ISRA inspection solution, DS Smith increases the quality of its products, continuously reduces production costs and ensures the sustainable use of resources. In addition, seamless process control is ensured at the same time. The system strengthens the company’s market position and ensures a decisive competitive edge. The return on investment is usually achieved within twelve months.