AVT’s Helios Varnish Inspection Module shortlisted for Labels & Labeling Innovation Award

AVT has been shortlisted for the prestigious Labels & Labeling Innovation Awards for its Helios Varnish Inspection Module. The industry-first technology enables reliable inspection of clear varnishes and coatings in parallel to print inspection. It does so without requiring converters to alter their formulations.

The winner will be announced on 15 September at LOUPE Americas.

Clear varnish and coating defects have long been one of the hardest problems in label and flexible packaging production. Conventional inspection systems simply cannot see transparent coatings. For years, the industry’s only workaround was to stop the press and check manually. Another option was to add UV additives or optical brighteners to the varnish so defects could be seen using UV light.

It was a compromise that changed the formulation. It also added cost and complexity. Converters still faced mis-registration, misprints and varnish starvation. These defects often escaped detection until the finished product reached the customer. At best, converters detected them at the slitter rewinder station, when it was already too late.

“Every converter we speak to knows the varnish problem, and for years everyone has had to live with it. We wanted to solve it properly, without asking customers to change their varnish or their process. The market response has been remarkable – one in three Helios systems now ships with the module.
Being shortlisted for the Labels & Labeling Innovation Award is recognition of the impact this innovation is already having on label and packaging production.” Said Guy Yogev, VP Product & Marketing, AVT.

Varnish Inspection System: An Industry First, Delivered as a Retrofit

The patented Helios Varnish Inspection Module inspects clear varnish and coating layers directly. It identifies defects that other systems cannot detect.

The module works across matte, gloss and tactile coatings. It also inspects varnish alongside print, barcode, variable data and color measurement in a single platform. It operates at full production speed with no compromise on accuracy.

Just as importantly, converters can retrofit it to Helios systems installed from 2017 onwards. Converters can add the capability to equipment already on their pressroom floor. They do not need to replace the hardware. This approach has driven rapid uptake since the module’s introduction.

Value for converters, impact for the industry

For converters, the module delivers immediate operational value. It catches varnish defects, mis-register and starvation before shipment. This cuts reprints, waste, downtime and quality complaints.

These are the same workflow improvements that underpin documented customer productivity gains of around 30%.

The innovation also delivers broader benefits for the industry. By removing the need for UV additives and optical brighteners, the module simplifies coating formulations. It also supports cleaner, more sustainable production.

This represents a meaningful step for a segment under growing pressure to reduce material complexity and environmental footprint. For end markets where coating integrity directly affects product protection and brand quality, such as food and beverage, cosmetics and pharmaceuticals, the module raises the standard of finished-product assurance that converters can credibly offer their customers.

“Innovation in this industry has to earn its place on the pressroom floor,” added Guy. “It has to work at production speed, integrate with what customers already have, and solve a problem they actually feel. The Helios Varnish Inspection Module does all three, and we believe this recognition reflects the value it is already bringing to converters.”

AVT has been at the forefront of print inspection since 1992. The company helps printers worldwide achieve unparalleled quality and efficiency through automated systems. These systems deliver complete quality control at the highest production speeds.

The winner of the Labels & Labeling Innovation Awards will be announced on 15 September. The announcement will take place on the opening day of LOUPE Americas.

Visitors to LOUPE Americas can see the Helios Varnish Inspection Module in action at Booth #3523. They can also learn how converters are using the technology to improve quality, reduce waste and increase productivity.