Mixed copy detection ensures that the correct content has been printed on each folding carton, protecting you, the brand owner and the customer.
This is especially important when handling multiple similar versions of the same product with minor variations. Mistakes in the process can easily happen and be very hard to spot visually. Or even more so when printing composite sheets. Often, any error is only identified by the consumer, resulting in monetary loss of product with costs likely pushed down to the folding carton plant – but loss of customer confidence can be even more costly.
Preventing mixes by accurately reading printed codes and implementing solid best practices to guarantee quality is one of the most critical functions for any quality carton producer.
Read ahead to learn about inspection options available and unique ways Monet software technology can ensure against mixes.
Choosing a Mixed Copy Inspection Solution
Leary offers both sensor and camera solutions to successfully monitor for mixed copy. All solutions are compatible with MaQ+ and Array controllers and are easily implemented on multiple machines including folder gluers, die-cutters, window machines, tray-formers and more.
When choosing a solution, consider these options and variables:
Pharmacode Sensor Solution:
- Inspects monochrome and multi-color binary codes
- Inspects for missing process color
- Pass / fail logic only
- Single linear reading path
Laser 1D Sensor Solution:
- Inspects all linear 1D type codes (EAN, UPC, I 2 of 5, etc)
- Very easy to setup
- Added flexibility from pass / mix / no-read logic
- Multiple reading paths are more tolerant of minor print defects
iCode 2D Code Reader:
- Barcodes can be printed in any orientation without impacting speed
- Most tolerant, can read even blurred codes successfully
- Displayed camera image helps operators to optimize setup
5 Best Practices for Preventing Mixed Copy
The best performing mixed copy solutions are properly maintained through standard operating procedures. Monet’s automated software technology ensures your mixed copy solution is optimally running.
Enhanced Mixed Prevention.
Allows only one barcode learn to be completed per job, preventing operators from inadvertently relearning a mix. The barcode can be relearned without changing jobs only by using in a manager-level password or fingerprint.
Barcode Challenge Feature.
Any mix prevention SOP should include regular challenge tests to verify system performance. A specific barcode value can be programmed into Monet so that when a “challenge label” is applied for the regular test, Monet recognizes this special code and timestamps and records the ‘Barcode Challenge’ being performed. Reports can be generated from Leary’s iQ reporting software proving these mix quality checks have been conducted.
Job Settings Revert to Default.
Identified CTQ (critical to quality) settings can automatically revert to a predetermined default value whenever a new job is started, regardless of any deviation that has occurred previously. This further ensures any changes to barcode or other critical tolerances, overridden by a manager level password / fingerprint for production related reasons, cannot be inadvertently left changed. These changed setting from one job may have the potential to weaken weaken the systems overall security.
Password Portal Access.
Maintaining system settings are vital to maintaining quality. In addition to fingerprint reading, Leary’s simple password portal allows access to a rolling manager level passwords via a web-based link. For unique situations requiring exceptional overrides to tolerances or quality check options, passwords can only be requested by pre-authorized users. These changes are recorded with who, when and why the password was being requested.
Alarm Protection.
Alarms can be locked on, password protected or set to automatically re-enable after X time or speed. This ensures that security is maintained while allowing make-readies to be performed, achieving maximum production throughput.
Mixed copy inspection is vital to ensuring quality product and can be achieved simply with Leary’s solutions. Contact our technical sales team for assistance with these solutions and best practices for your plant.
