Gintzler Graphics, New York, USA, has installed a 13 inch (330mm) wide flytec 2010 slitter inspection from AB Graphic International. The full specification machine will be used to convert and inspect high quality labels for the pharmaceutical market.
Bryan Scheible CEO, Gintzler, commented, ‘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 inkjet for serialization during fina
l 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’.
The flytec 2010 includes a bi-directional unwind/rewind, and fleyeVision 100 percent print face inspection equipped with 4096 pixel, grayscale 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.
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 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 customized 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 meets 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.
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.’
Michael Leidgschwendner, managing director of AB Graphic International, added, ‘Bi-directional operation means that every defect can be checked twice by moving the web backwards and forwards.’ 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 inkjet printing heads can be independently controlled.’
‘This is the third system we have supplied for the label converting operation at Gintzler Graphics’, said 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.’
Pictured: (L-R) Michael Leidgschwendner, managing director of AG Graphic International, Germany and Bryan Scheible, CEO of Gintzler