• Overview
  • How it works
  • Benefits
  • Optional Modules
  • Resources

 

100% Quality Assurance for HP Indigo 30000 Folding Carton Digital Press

 

AVT Apollo 30K is uniquely designed for the HP Indigo 30000 Folding Carton press, featuring a dedicated end-to-end solution for 100% sheet inspection with various workflows. A robust and reliable automatic 100% quality assurance solution exclusively for digital folding carton applications.

 

Apollo 30K automatically detects print and substrate defects, ensuring and verifying print content.  The system automatically ejects defective sheets to the ejection tray when large or continuous defects are detected, or alternatively, tracks individual packages downstream, ejecting them at the folder gluer stage.


Integrated into the Tresu inline iCoat unit, the Apollo 30K inspects the quality and validity of every printed sheet. The system immediately alerts on process and trend issues that can be resolved by the press operator, as well as recording all defects into the system database.

 

The Apollo 30K system significantly decreases production time, supports the shorter runs of digital printing, automates manual processes, and provides valuable waste savings.

 

The system’s high resolution and high speed ensure print quality, data validity, barcodes and numbers tracking, as well as DeltaE color monitoring – all in one pass!

 

 

 

Apollo 30K detects a variety of print defects, including color variations, misprints, low contrast defects, mis-registration, spots, and splashes.

The system visually indicates the precise location and type of each defect, while in parallel, the system records all relevant defect data into roll reports. An easy to view color-coded light tower informs operators when a defect is detected, so that errors can be addressed and corrected in real-time.

Apollo 30K provides full process control and trend monitoring, in addition to a comprehensive quality assurance package and ejection mechanism.

 

Workflow, Archiving & Reporting

The ZeroSet module enables JDF connectivity with an Esko Automation Engine to continuously inspect 100% of the printed material while jobs and designs are changing on press

Equipped with a built-in PrintFlow module, the system automatically stores all job data in job archiving for fast setup in the case of reprints, while detection data is logged into the system’s roll and job reporting, including defect location, defect images, and print quality statistics. Operators use in-line reporting to review job/order/roll reports, edit and export final reports to digital files, or to AVT WorkFlow Link to automatically connect to rewinders or slitters, and efficiently remove defective material prior to shipment. The system’s PrintFlow Manager collects relevant PrintFlow data from multiple systems, so that managers and key personnel can easily monitor, analyze and control production quality from their desktop PCs.

 

Boosts Productivity

Apollo 30K ensures consistent print quality on every job, significantly increasing overall press productivity and short runs printing. Users benefit from fast ROI and save valuable time and resources with exceptional fast and easy press set-up and deployment. In turn, customers benefit greatly by reducing waste, resources and production costs, while preventing customer rejections.

 

Unmatched Print Quality

Apollo 30K delivers 100% quality assurance and print process control, with full support of all web presses, substrates, and applications. The system detects and alerts on a wide variety of print defects, visually indicates the precise location and type of each defect, marking them for further analysis, archiving and reporting, to achieve 100% quality on every print job.

 

Innovative Print Inspection Process

Fully-automated, the Apollo 30K inspection process provides an intuitive user interface, equipped with an easy-to-use online guide, minimizing job set-up time, and detecting critical defects in real time. The system categorizes defects according to defect type, with easy on-screen view, and indicates the precise defect location on the full repeat image.

 

Works seamlessly on any application and substrate

Supports all web press substrates and applications, including transparent and flexible substrates, foils, paper and cartons, used in the wide web folding carton industry.

 

Barcode verification

100% verification of printed barcodes; checks/alerts for barcode

decoding, quality and ANSI grading.

 

Ejector Interface

Automatically triggers any marking/ejecting device to eject

defective sheets.

 

Regions of Interest (ROI) and “step and repeat” setup

All required setup can be done on one package and automatically set to “step and repeat” on all other packages. The system enables setting different sensitivities/profiles to different regions in the package, for enhanced detection in key areas, or to reduce sensitivities in less critical areas.

 

Inspection Profiles

Fast, easy generation for seamless set-up and improved control of quality standards.

To further support the folding carton and labels industry, all predefined Apollo 30K bundles include a rich and varied selection of optional add-on modules built to enhance and support your print inspection process, ensuring 100% quality assurance and process control on every print job.

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Job Verification Tools

To prevent costly production errors, job verification is performed early in the process, during the set-up stage. AVT’s verification toolset includes a robust PDF comparison module that compares every new job to the original PDF digital file or to the previously saved master image in case of re-runs

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Color Measurement & Monitoring Techniques

AVT’s inline color monitoring and measurement solution offers a variety of modules to support the entire workflow. Inline Delta E color monitoring enables a simple, standard method of alerting on color deviation during print run. In parallel, an inline spectrophotometer delivers real inline, ISO standard, dual-beam spectral color measurements on existing color targets or in image areas for absolute, accurate L*a*b*, density, and dot gain measurement with enhanced reporting and a complete color workflow

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Workflow Support

Apollo 30K’s range of workflow modules help accelerate overall print production via seamless transfer of quality data from the press, to efficiently remove defective material. AVT Workflow Link automatically stops the rewinder at the relevant defect location, saving valuable time and resources, and automating the quality assurance process

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Data Collection & Automatic Storage

In order to efficiently collect, analyze and edit the quality PrintFlow data collected by the Apollo 30K inspection platform, a data management tool (PrintFlow Manager) provides key users with remote data access directly from their desktop. PrintFlow Central is a central automatic storage of job data and roll reports, supporting central automatic backup of all data, and enabling continuous availability of inspection data at all times, for analysis, management, and complete workflow downstream

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Setup & Automation Tools

To ensure quick and secure system setup, save on production time, and guarantee high quality standards, several Apollo 30K modules were designed. Modules include communication with existing MIS (ERP) systems in the production facility, and remote system setup using offline setup utilities to prepare jobs in advance. The ZeroSet option enables automatic system setup for both conventional and digital presses, through connectivity with Esko’s automation engine and pre-press data

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