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


Helios Product Line – robust 100% automated inline inspection solutions for label and narrow web printing

With over 2,000 installations worldwide, the AVT Helios product line is a market-proven automatic 100% inspection solution designed for labels and other narrow web printing applications. Helios automatically inspects printed labels or packages for defects and imperfections, delivering exceptional quality results and eliminating customer rejections. Raising the bar on automatic print inspection, Helios supports every stage in the production process. This is achieved through AVT’s innovative platform that serves the widest available range of print production workflows.

Built to Deliver on Press or Rewinder
The Helios product line delivers the highest available inspection resolution and speed on the market today. With rigorous process control across the entire print production process, Helios does not disappoint. Installable on any press or rewinder, Helios instantly identifies defects on labels as soon as they occur, reducing waste, boosting performance, and delivering 100% quality assurance. This means your print jobs are in good hands – verified from setup through printing and finishing.



Helios Models: Comprehensive Process Support
The AVT Helios product line supports every stage of the print production process – with a comprehensive range of print scenarios and workflows, including:


Helios R / Helios B                      100% inspection that delivers the best cost-effective solution
Helios S                                          Supports demanding reflective and holographic, high-quality applications, and any production workflow
Helios S Turbo+                            Combines superior inspection performance with advanced high-speed process control
Helios Turbo HD / Turbo HD+    Market-leading inspection performance for high-end applications

Helios automatically detects defects such as missing labels, defects in character areas, color variations, miss-registration, missing print, spots, imperfect matrix peeling, die cut registration, and more. To achieve superior inline quality assurance and process control, Helios is quickly and easily installed on any press or rewinder, including a slitter rewinder. Helios can also be installed on other types of finishing equipment, as it supports current and future converting equipment, regardless of machine speed, width or technology.


Printing Press

When installed on a printing press, Helios operates as an inline quality assurance and process control solution, alerting on potential print problems and recording every relevant defect. Via an integrated reporting mechanism from press to rewinder, the WorkFlow Link module (optional) is later used for downstream repair on the finishing machine or in quality reports for the end-user. Helios is also equipped with a built-in PrintFlow module, where operators use inline reporting to review job/order/roll reports, edit and export to digital files, or print reports for later material handling.



When installed on a rewinder, Helios seamlessly controls the rewinder, creating a combined automatic inspection station. The system automatically inspects 100% of the labels or packages and stops the rewinder at defect locations to clean the defective parts before the roll is sent to the end-customer.

Works seamlessly on any application and substrate
Supports all label stock, paper and plastic label stock, flexible, transparent & opaque films, paper & cartons, and thick embossed metalized foils, as well as highly reflective holographic foils and laminates 

Fast & easy job setup
In one minute (or less), Helios is up and ready to go! Jobs are automatically saved and loaded for fast setup or repeat jobs, while several available options can automate the setup using offline stations, MIS connectivity, or pre-press information


On press
Significantly reduces waste and production costs, decreases re-prints, and boosts overall productivity and efficiency


On rewinder
Automatically stops at the defect location and enables easy roll clean-up, delivering 100% quality assurance and eliminating customer rejection


Online monitoring and robust built-in reporting
Online tool tracks and reports total good material to be printed, while all detection and monitoring data is collected and stored in the system’s reporting mechanism







All predefined Helios Product Line bundles include a rich and varied selection of optional add-on modules built to enhance and support your print inspection process, guaranteeing 100% quality inspection on every print job.


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.


Color Measurement & Monitoring Techniques

An integral part of the print inspection process, inline color monitoring and measurement offers a variety of modules to support the 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.


Barcode & Variable Data Verification

AVTs’ barcode and variable data verification enables label printers to inspect and verify 100% of the printed 1D and 2D codes as well as human readable items. It detects and alerts on any duplications, missing codes, barcode quality and readability, or any other code validity concerns. The system can compare and validate printed codes against the original database, and export complete reports per roll or job.


Workflow Support

Possibly the most important component of any print job is its workflow – the key to streamlining and standardizing the steps required to carry out a task. AVT Helios’ range of workflow modules help speed up overall print production via seamless transfer of quality data from the press to the rewinder 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.


Data Collection & Automatic Storage

In order to efficiently collect, analyze and edit the quality PrintFlow data collected by the Helios inspection platforms, 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, and supports central backup of all data, enabling continuous availability of inspection data at all times for analysis, management, and complete workflow downstream.


Setup & Automation Tools

The success of any print production process rests on process automation. To ensure quick and secure system setup, save valuable production time, and ensure consistent quality standards, several AVT Helios 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, through connectivity with Esko’s automation engine and pre-press to enable fully-automated setup and inspection for both conventional and digital presses.

Learn More
Learn More
Learn More
Learn More
Learn More