AB Graphic International has announced the installation of a 13" (330mm) wide flytec 2010 slitter inspection rewinder to New York, USA based Gintzler Graphics, Inc. The full specification machine will be used to convert and inspect high quality labels for the demanding pharmaceutical market.
Commenting on the purchase, Bryan Scheible CEO, of Gintzler said, "We made the decision to acquire the flytec 2010 because we wanted to enhance the level of service to our critical care clients. The market we serve demands perfection and we wanted to have the latest technology. We needed a platform that could interface with Domino Ink Jet for serialisation during final inspection. We are also a multi plant facility so we were looking for a vendor that could service all our facilities and offer remote diagnostics.
Key elements of the flytec 2010 at Gintzler Graphics include bi-directional unwind/rewind, and fleyeVision 100% print face inspection equipped with 4096 pixel, greyscale camera capable of detecting defects to a minimum size of .0000465 square inches (0.03 square mm) at speeds up to 22.2f/pm (120m/min.) Labels with static and dynamic 1D and 2D bar codes can be checked to ANSI standards. The system also permits labels to be compared against pre-press created PDF files as well as taught to read the 'golden image' data.
"This equipment is used to perform the final inspection of the label prior to shipment and has also automated the required leader and trailer function needed for each roll of labels shipped," added Scheible. "The comparative vision system on the flytec proved superior to its competitors and the software was customised to generate image capturing documentation for client reporting purposes. We were able to work closely with AB Graphic International who set up a full integration team to ensure the machine functions met our unique requirements".
Equipped with pharma control module the flytec 2010 is designed to meet high USA legislative requirements for pharmaceutical labels and records all operator access and parameters carried out per job and produces all validation documents including IQ, OQ and PQ. Any defect found is recorded in the extended protocol software with photographs to enable subsequent static evaluation.
Commenting on the strengths of the equipment, "Scheible said, "This equipment is built to withstand the normal wear and tear of daily production and can interface with shop floor management systems. Through-put speeds are consistent and the accuracy at which the flytec detects non-conforming material is superior to other equipment tested. This enables us to deliver a better quality product." In terms of unexpected benefits, Scheible explained, "Our products supply high speed label application lines where label position to the liner edge is ultra-critical. The slitter assembly maintains exact positioning using ultrasonic label edge guide feeding data to the slitter servo to maintain the slitting parameters. This feature has allowed us to keep tighter tolerances on our label to liner edge requirements, reducing in process adjustments by our customers. We are always looking for new technology to improve our process and the flytec has allowed us to exceed expectations. This piece of equipment greatly supports our zero defect initiative."
"Bi-directional operation means that every defect can be checked twice by moving the web backwards and forwards," added Michael Leidgschwendner, Managing Director of AB Graphic International. The first allows the operator to check if the defect can be replaced and/or make a repair and the second enables re-inspection to ensure the subsequent operation is error free. Multi-lane, bi-directional operation can be carried out simultaneously with slitting and inkjet printing for numbering as the machine is equipped with an accumulator that makes it possible to combine these and all other finishing steps in one operation. Up to eight ink jet printing heads can be independently controlled."
The flyCut slitting control unit supplied with the Gintzler Graphics system includes a camera that checks web edge matrix movement and controls the unit to prevent inadvertent damage to labels. A label dispenser unit designed to remove labels from the start or end of the roll creates a blank web to ensure all remaining labels have been inspected.
"This is the third system we have supplied for the label converting operation at Gintzler Graphics added Leidgschwendner. The first was a flytec 150 for integration with an inkjet printer and the second and third include the flytec 2010 model and an HSR slitter/rewinder destined for the company's Texas facility."
Established in 1916, Gintzler Graphics is independently owned and serves a wide range of industries for the production and supply of labels, tags, paperboard packaging and speciality converting using both traditional and digital label printing processes. The company offers a range of services from design to finished product and has received numerous awards for print quality. Custom effects and decorative options include foil, screen and embossing.
AB Graphic International is a worldwide supplier of converting and finishing machines for labels and packaging with facilities in the UK, Netherlands, France, Spain, Germany and United States. The company has become a market leader in supplying fully modular digital converting lines and label inspection and standard or turret rewinding systems. Specialist applications include RFID insertion, laser die cutting, booklet labels,100% print face inspection and custom built lines tailored to meet market demands.