100% Automated Inline Inspection for Label and Narrow Web Printing
AVT Helios is a market-proven, automatic 100% inspection solution for labels and narrow web printing that ensures quality by identifying defects instantly on labels or packages, minimizing waste, and enhancing overall performance.
How AVT Helios Works
AVT Helios auto-detects various defects, such as missing labels, color variations, miss-registration, and clear varnish defects, offering superior inline quality assurance. Easily install on presses, rewinders, and other finishing equipment, supporting a wide range of machines, speeds, widths, and technologies.
AVT Helios
The Benefits of Automated Inline Inspection
Works on All Applications & Substrates
Supports a wide range of label materials, including paper, plastic, films, cartons, embossed metalized foils, and holographic foils.
Fast & Easy
Job Setup
Jobs are automatically saved and loaded for fast setup or repeat jobs. Automate setup using offline stations, MIS connectivity, or pre-press information.
Online Monitoring & Built-in Reporting
Automatically stops at the defect location and enables easy roll clean-up, delivering 100% quality assurance and eliminating customer rejection.
Install on Any Printing Press or Rewinder
On Rewinder
Track and report printed material quantity, while storing data in the system’s reporting mechanism.
On Press
Reduce waste and production costs, decrease re-prints, and boost productivity and efficiency.
Three Levels of Precision Tailored to Your Printing Needs
AVT Helios Core
100% inspection for all printers
Resolution starting
from 100 microns at 350 mm
Resolution-to-speed technology: dynamically scaling 4k resolutions
AVT Helios Turbo
100% inspection for high end printers
Resolution – Fixed at 100 microns,
independent of width or speed
Resolution-to-speed technology: High-speed multi resolution camera
AVT Helios Ultra
The most advanced inspection system in the world for highest standards
Resolution – High-speed & high resolution combined at 65 microns independent of width or speed
Resolution-to-speed technology: Ultra-speed multi resolution cameras
Optional Add-On Modules
Varnish Inspection – Winner of the 2026 Labels & Labeling Innovation Award
Inspects clear varnish and coating layers directly, in parallel with print inspection and at full production speed.
Defect Detection Detects varnish mis-registration and partial or full varnish starvation on matte, gloss and tactile coatings.
No Process Changes Works without UV additives or optical brighteners, and with no change to the varnish or the printing process.
Retrofittable Can be added to existing Helios systems as an upgrade.
JobRef Enables job verification at the setup stage by automatically comparing the job to the original, customer-approved digital PDF file.
MasterRef Prevents production errors and reduces waste by enabling printers to save a master image of each job, which is later used to verify that repeat jobs are identical to the original.
Clear Missing Label Detection Detects missing or partially missing clear, non-printed labels on Helios LED-based systems. When a label is absent or not fully adhered, the system alerts the operator and stops the rewinder.
Continuous and Random Monitoring Classifies process and random defects and alerts the operator, so production issues are identified and corrected quickly.
Low Contrast Monitoring Detects and displays low-contrast issues such as hazing and scumming.
Repeat Length Trend (RLT) Monitors repeat size and alerts on trend changes, with no additional sensors required.
AutoSet Connects prepress directly to the inspection system, eliminating manual job setup, saving time on press and keeping quality standards consistent.
ProMIS Enables two-way communication with MIS (ERP) systems in the print production environment for fast, simple and secure setup.
Offline Setup Prepares inspection jobs remotely from digital PDFs, saving valuable time on press while maintaining quality standards.
Barcode & Variable Data Verification Provides 100% verification and ANSI-based grading of 1D/2D barcodes and variable data, including human-readable codes. Every barcode is checked for defects and readability, with alerts on barcode quality, missing codes, duplications and sequence issues.
AutoEdit AI Classifies every defect after inspection as salable, non-salable or needing review, so operators only check the questionable ones. Works inside PrintFlow Manager and logs every decision for a full audit trail.
WorkFlow Link Bridges press and rewinder by transferring quality data from the press, so the rewinder stops automatically at each defect for efficient removal of defective material.
PrintFlow Manager Gives remote access to PrintFlow data from all installed inspection systems.
PrintFlow Central Automatically backs up all PrintFlow data, keeping inspection data continuously available to PrintFlow Manager and WorkFlow Link.
IΔeal Monitors Delta-E inline anywhere in the image, in parallel with print inspection, and shows color differences in a graphic view.
SpectraLab XF An inline, ISO-compliant, dual-beam spectrophotometer that measures color in dedicated patches and in image areas, delivering absolute, accurate L*a*b*, density and dot gain values with enhanced reporting and real-time process control and alerts.
Customer Testimonials
We were able to reduce production costs by 25%, increase productivity by 30%, and reduce preparation time for all jobs. We also have zero complains from our customers now
PLASTICA
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We increased productivity by about 30%. We reduced paper wastage, unnecessary re-prints, time and machine stops. In term of quality, 99% of defects are removed now prior to shipment
AG3M
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With SpectraLab XF, we can guaranty to our customers that each package we print is in good color and all inks are in the proper Lab value. This is an important selling point for us during our discussion with our customers
In addition, we save setup waste of 250-300m per order, since we do not need to stop the press and take color measurements for color approval
WIPAK
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Get Started with AVT Helios
Explore AVT print inspection solutions for cutting-edge process control, quality assurance, and print management for packaging, labels, and commercial print production.
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