Consolidated Label adds inspection systems

Consolidated Label has purchased six BW Converting Baldwin Guardian PQV inspection systems for its slitter-rewinders since early 2024, with an additional system now being installed on a 22-inch Nilpeter press, as the converter raises its print inspection standards to meet more selective printed packaging buyers.

The first phase of deployment focused on pharmaceutical and nutraceutical work, where tolerance for print imperfections is especially low. Consolidated Label placed the systems downstream on slitter-rewinders rather than changing its pressroom philosophy, preserving flexo throughput while adding a higher level of inspection before the final product shipped.

'We couldn't just rely on the flexo operator anymore. We had cameras on different presses, but the eye and the quality sensitivity of the customer had changed. That's really what drove us to add another level of inspection before those labels went out the door,' said Charles Mitchell, COO of Consolidated Label.

Consolidated Label spent months refining the systems' settings based on customer requirements, material types, laminates, foils and defect patterns. Mitchell said the effort has reduced customer complaint dollars and raised customer satisfaction, and has also changed the productivity equation on the finishing side, with speeds on some slitter-rewinder applications nearly doubling from around 100 to 140 fpm into the 200, 300 and in some cases 400 fpm range. The technology has also shortened the operator learning curve on slitter-rewinders from six to eight months to closer to 90 days.

With six off-line systems in place and a seventh moving onto press, Consolidated Label is beginning to push inspection further upstream.