Follow along with a Q&A from PostPress Tech Watch on Leary’s solution for mixed copy detection on die cutters utilizing a Leary system.
1) What does Leary’s mixed copy detection on die cutters offer that is new/better than what was previously available?
Leary offers a simple, cost-effective solution for adding mixed copy detection to die cutters, further guaranteeing quality product is delivered to customers. Monitoring mixed copy on die cutters allows plants to detect for mixed sheet, blank sheet, wrong load and reverse load sheets early and upstream during production. Laser 1D code reading options include accurate verification of all ANSI barcodes, including Code 39, Codabar, Code 128, 1 2 of 5, Code 93 and UPC/EAN. There is also the ability to monitor for 2D codes printed on a sheet which can save space.
The flexibility of this solution allows for the detection scanner to be mounted in various locations depending on the machine, as well as the option to scan on the top or bottom of the sheet. Detection accuracy at 11,000 sheets/hr is delivered as sheets are fed into the cutter. Product that does not meet code requirements will stop the feeder, before the sheet gets to the gripper bar, for safe and quick sheet removal.
Availability for previous mixed copy solutions left a gap in plants wanting a solution with seamless integration. Die cutters were not available with integrated quality inspection systems. Plants were often left to source their own sensor solutions.
2) What advantages does monitoring for mixed copy detection on a die cutter provide for the user? What extra value does it provide?
There are 2 main advantages when customer’s add mixed copy detection to a die cutter. The first allows plants to guarantee quality for unglued jobs that do not received inspection during another process, such as folding or gluing. Without mixed copy detection during the die cutting stage, product delivery may include a mixed sheet or blank sheet, resulting in poor quality product for a sheets worth of product, ranging from 6-30 products per sheet.
The second advantage to mixed copy detection on a die cutter is the increased quality inspection that is improved at each stage of carton/product production. During each process; printing, die cutting, folding/gluing, and more, quality is inspected and maintained to ensure that product quality remains at each stage. Additionally, plants may have a lag or storage time between printing, die cutting and folding/gluing that can leave room for human error.
3) What are some production challenges that monitoring for mixed copy on die cutters helps users overcome?
A product that goes through multiple production stages and movement before being shipped can increase the risk of poor quality. Ensuring there is proper automated quality inspection solutions at each stage can remove these risks and guarantee quality.
Minimizing waste; in the form of time, materials or finished product leads to a more efficient and sustainable plant. Mixed copy, blank sheet, and improper sheet loading inspection can remove multiple rejects on a full sheet of printed product. Monitoring for mixed copy on a folding machine or folder gluer can successfully reject a product – but that product has already been cut, folded and possibly glued; adding additional resources to a poor-quality product. Removing a rejected product earlier in the process, minimizes unnecessary waste.
4) How have customers responded to monitoring for mixed copy on die cutters?
Customer’s looking for quality in all areas of their production environment benefit from a mixed copy solution on a die cutter. The cost-effective MaQ+ controller delivers quality inspection with minimal setup time and is extremely consistent.
The simple setup and ease-of-use during production leads plants to purchased additional mixed-copy solution for multiple die cutters in a short amount of time – after the first successful implementation.
5) What is unique about the operating system of a mixed copy QA system on die cutters?
Leary’s MaQ+ controller utilizes easy-to-use Monet operating software. This software has unique technologies to deliver the most accurate scanning solution. Software setup is simple with a ‘Learn Barcode’ feature assisting in quick job changeovers. The clean visual display on the controller gives a quick assurance that product is being accurately monitored.
For more information about implementing a mixed copy quality assurance solution into your production solution, reach out to [email protected].