SOLUTIONS FOR PACKAGING

TOTAL QUALITY CONTROL AT 360°

 TQC-360°, THE CONCEPT OF DEFECT-FREE PRODUCTION
AND WORKFLOW MANAGEMENT IS RENEWED
WITH THE RANGE OF PRODUCTS CALLED “PLUS”

TQC-360° (360° TOTAL QUALITY CONTROL) is Grafikontrol’s innovative modular

platform, developed to offer printers a complete solution to guarantee quality.
Grafikontrol’s TQC-360° concept is not limited to quality control for the printing and
converting industry but extends by integrating into all stages of production (Industry
4.0), applications, processes and services.
Our 360° approach to the customer combines very high-performing products and
excellent service.

The TQC-360° products integrate into any web application. Customers benefit from the
modular design which allows them to start with the features they need and upgrade at
any time.

The components that make up the TQC-360° line can satisfy any customer need. They
can operate separately or together through a single operator interface if desired. Tailor
made solutions can be designed to fit non-standard applications.

INSPIRED BY TECHNOLOGY
Grafikontrol has been recognized as worldwide leading manufacturer of high
performance equipment for the graphic industry for more than 50 years. We marry the
best of high-tech components with the essence of Italian engineering to manufacture
best of industry products with a heart “Made in Italy”.

2
 SOLUTIONS FOR PA C K A G I N G

ALL GRAFIKONTROL SYSTEMS ARE DESIGNED TO BE CONNECTED

TO EACH OTHER TO SATISFY THE “INDUSTRY 4.0”
OR SMART MANUFACTURING TRANSFORMATION PROCESS,
FOR INDUSTRIAL AUTOMATION

PRODUCTS
• WEB VIEWING
• 100% INSPECTION
• IN-LINE SPECTRAL
COLOR MEASUREMENT
• WORKFLOW & WASTE
TRACKING
• REGISTER CONTROLS

APPLICATIONS
• PRINTING
• REWINDERS
• EXTRUSION
• FOLDING CARTON
• METAL DECORATION
• TEXTILE
• METALIZATION

PROCESSES

SERVICES • GRAVURE
• FLEXO
• OFFSET
• REMOTE CONNECTION &
• DIGITAL
ASSISTANCE
• EXTRUSION
• LOCAL SERVICE
• SERVICE CONTRACTS
• 15 YEARS SPARE PARTS
AVAILABILITY

3
EFFECTIVE AND INNOVATIVE SOLUTIONS
FOR HIGH QUALITY PRINTING

TECHNOLOGICALLY ADVANCED PRODUCTS AND

COMPREHENSIVE SERVICES FOR PERFECT PRINT
Grafikontrol develops and manufactures the most advanced and performing equipment with
state-of-the-art solutions to ensure packaging converters the maximum in terms of quality
control. The range of application of Grafikontrol systems is very wide: from conventional
printing methods to digital on all substrates including metal printing, extrusion, lamination,
textile and finishing.
A printing line equipped with Grafikontrol press controls can include 100% print/coating
inspection, register control and inline color measurement in order to achieve perfect results
for every process: gravure, flexo, offset and digital.

Inspection - During the different processes, defects are automatically detected and stored in
a data base, the roll map files are then used to remove the defects during the finishing phase.
Register - The print register control uses sophisticated algorithms to maintain accurate color
to color register for the different press dynamic conditions.
Color - A dedicated spectrophotometer assures color consistency.
Additionally, Grafikontrol provides prompt and effective customer service via remote and local
assistance backed by a post-sale spare part guarantee of 15 years. For more than 50 years
Grafikontrol has been recognized as a leading solutions provider to the converting industry.

LAMINATION / SLITTER /
GRAVURE FLEXO OFFSET DIGITAL
COATING REWINDER
MATRIX PLUS

MATRIX C/S

PARVIX

LYNEX PLUS

LYNEX C/S

PROGREX PLUS

EASY TRACKER

CHROMALAB

CR33-CR34

4
 SOLUTIONS FOR PA C K A G I N G

WEB VIEWER & page 8

STATISTICAL PRINT INSPECTION
Using the latest camera technology, the system reproduces the image of the printed
web with excellent quality at any production speed. The 16X zoom allows analysis of
the print details down to the dot.
• Digital matrix camera with 9.6 Megapixels resolution assures great image quality and
realistic color reproduction
• Four LED illuminator groups provide perfect light distribution for inspection on any kind of
substrate, including metallized
• Multi-touch monitors guarantee fluency and ease of operation
• The menu driven interface gives the operator full control of the printing conditions
• Statistical inspection of the print with synoptic alarms when defects are detected
• Register presetting (Click&Drag© for CI flexo)
• Barcode verification
• Δ Color monitoring
• Print repeat measurement and trend display

FRONT TO BACK DUAL CAMERA SYSTEM page 14

FOR INSTANTANEOUS REGISTER COMPARISON

This dual matrix camera system allows instantaneous display of front and back print
for the real-time verification of top to bottom register. The system instantly shows
the individual images of print side and cold-seal/coating side plus a precise top +
bottom overlapped image for the evaluation of the register deviation.

• Continuous scanning of the entire print repeat, through data input of job specifications, print
repeat and web width
• Manual and automatic camera movement on preset selected positions
• Camera positioning via icons on the multi touch screen graphic interface
• Real-time visualization of the front side (print), back side (cold-seal) and overlapping of both
allowing detection of longitudinal and side register variations
• Optics and illuminators are custom made design to get the best performance on any kind of
substrate
• Internet connection for remote assistance

SIMPLE&SMART WEB VIEWER page 16

The system provides high performance and allows with its ease of operation
to view printed images in real-time with magnification of the details up to the
printing screen.

• “Full color” image processing on any type of substrate by using an RGB matrix camera
• Continuous scanning of the whole print repeat
• Up to 32 positions can be stored for the camera in the print repeat, with the possibility to
differentiate zoom, iris and focus for each image
• Camera positioning via icons
• Manual and automatic camera preset in selected positions
• Internet connection for remote assistance

5
 100% PRINT INSPECTION page 18
Your customer’s demand for total control is satisfied by our 100% inspection. The
LYNEX PLUS assures inspection of the entire print repeat, categorizing and storing
every defect detected during production. The system provides this data in roll maps
and generates production reports for subsequent analysis and workflow use.
• Real-time process analysis, the system operates at web speed up to 1000m/min with clear
discrimination of defects by size and type
• The latest generation 8K-pixel RGB linear cameras allow you to detect defects up to 0.05
mm in size on printed or neutral substrates
• Alternatively, for simpler or cheaper applications, 8K-pixel “bilinear” cameras can be used
• Job reports and Waste management
• Integration with MATRIX PLUS area camera for detailed image investigation when needed
• Real-time display of the entire print repeat on a UHD wide screen monitor at any production
speed

100% INSPECTION FOR TRANSPARENT page 22

VARNISH, COATING AND COLD-SEAL
Inspection system to detect defects related to coating processes for varnish,
lacquers and cold-seal.
• Clear discrimination of varnish or coating defects from the print ones
• Detection of defects by size and type
• Sensitivity adjustment for each type of defect
• Display of the defects map for each roll in process
• Quality reports for each printed roll
• Database containing 6 months of production
• Internet connection for remote diagnostics

COMBINATION OF 100% INSPECTION page 24

+ WEB VIEWING
The inspection of a wide web is not optimal using only a viewer or a 100% system.
Press operators need a tool that can guarantee them total quality control. The
combination of line scan cameras (LYNEX PLUS) and area cameras (MATRIX PLUS)
fully satisfies customer requirements for the entire process control.
• Full integration of LYNEX PLUS and MATRIX PLUS systems including their functions, all
managed from a single operator interface
• Intuitive multi-touch screen gives quick and easy access to all components and functions
• The area camera and the 100% inspection work independently: the full web inspection is not
compromised when press operator uses the area camera for viewing fine print details
• The Touch&View function moves the area camera to a desired position simply by touching a
point on the print repeat display screen

6
 SOLUTIONS FOR PA C K A G I N G

DEFECT TRACKING THROUGH VARIOUS

PROCESSES, WASTE MANAGEMENT &
page 26
DEFECT REMOVAL
Brand new and revolutionary defect coding system for the traceability of defects
detected during the various production phases. With this system, the efficiency of
the entire production process is increased as the data collected upstream allows
the slitter (or any finishing process) to be automatically stopped for the removal of
defects.
• Accurate tracking and localization of defects by synchronizing them to a variable code (sync-
code) printed by an ink-jet on the edge of the web
• Each sync-code contains information relating to the job no., Reel no. and length of the reel
being processed
• System applicable to any manufacturing process: extrusion, printing, lamination with
connection to the slitters
• Removal of waste by a fully automatic stop in the finishing phase (slitter)

IN-LINE SPECTROPHOTOMETER page 28

Provides real-time measurement and color information on start-up and during
production.
It can read from either dedicated color patches or the image area itself.
• Provides real-time color measurements: spectral curves, ΔE, L*a*b* values, Density, Dot
Gain
• Uses a motorized traverse for automatic positioning on the color bars or directly on selected
areas of the image
• The system provides an accurate match with all major brands of handheld spectro-devices
• Quick color matching: when the measured data is out of specification to the master, the
values are sent directly to the ink room where a correction dose is formulated to bring the
color back into tolerance

COLOR REGISTER CONTROL page 30

The CR33 - CR34 register controls have been developed using the latest electronic
and software technologies that, by selecting the best correction algorithm, reduce
waste during start up, ramp up, splice and re-start.

7
STATE OF THE ART
WEB VIEWING SYSTEM AND
STATISTICAL QUALITY CONTROL

MATRIX PLUS is the basic component of the TQC-360° The modular design offers the opportunity to configure
family. Its primary function is to provide the highest the system as the customer wants: from a simple print
image quality and zoom. The 9,6 Megapixel color viewer, MATRIX PLUS can be expanded with multiple
digital camera combined with the new generation of functions and options to transform it into a high-
high efficiency LED illumination allow snapshots of the performance device for print quality control.
running web with dot-sharp images from any printing The “full optional” version allows operators to detect
process and substrate. the most common defects not visible to the human eye
The powerful hardware and the new multitouch operator and to check the uniformity of the printing process.
interface guarantee high performance, fast settings and
quick operations. Intuitive graphics, similar to tablets,
makes it easy to operate even for beginners.

8
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

MATRIX PLUS is offered with a standard 3CCD digital color camera with 2064 x
CONFIGURABLE 1554 pixel (9,6 Megapixels), field of view 240mm x 200mm. In order to guarantee
reliable image quality, each system is supplied with optical motorized zoom and
VIDEO CAMERA a selection of illumination methods for the different substrates and features that
FOR ANY NEED the operator will encounter. Both systems use a 16X optical that allows analyzing
critical areas of the image in extremely fine detail, down to the dot level.

With MATRIX PLUS, Grafikontrol is on our fourth generation of LED illumination.

ILLUMINATORS The new four-banked light modules are much more powerful and allow even
FOR INSPECTION ON light distribution for any substrate. Special attention has been given to the optics
required to inspect metalized substrates (front printing or cold-seal). The LEDs
ANY SUBSTRATE ensure constant light over a practically unlimited lifetime.

MAXIMUM UPTIME The user-friendly interface associated with intuitive graphics and our multi-touch
features ensure a fast learning curve and impressive immediacy in initial set-ups
WITH MINIMAL and adjustments during the job run. With simple finger gestures the operator
easily selects screens or functions. The system operates with a multi-touch non-
EFFORTS glare 24” HD 16:9 monitor.

MULTI-TOUCH
OPERATOR
INTERFACE

9
 SYSTEM FUNCTIONS
• Continuous Scan: autoscan inspection of the entire print repeat.
• Stored Points: the camera moves to pre-programmed areas of the print.
• Image Stabilizer: the image on the screen, very often oscillating due to the web
elongation, is stabilized thanks to sophisticated software algorithms.
• Print Repeat Tab: virtual reconstruction of the entire print repeat allows the operator to
control the camera positioning.
• Split Image: allows a quick live/master comparison of the image.
• Quick-Zoom: “pinch-zoom” function allows a quick magnification of the image detail in
the desired area.
• More Controls: the basic system can be expanded with additional software and features
such as:
› Statistical Print Inspection
› Interactive Register© “click&drag”
› Barcode Verification
› Δ Color Monitoring to give complete control of color consistency during the print phase
• Total Quality Control: MATRIX PLUS can be easily integrated with the LYNEX PLUS 100%
Inspection for a complete control of the production runs and maximizing the quality
standards.
• Remote Support: the system is configured with a dedicated VPN connection for remote
support by our trained technicians.

FUNCTION
SELECTION

OPTIONAL FEATURES
• During the printing process the quality of the product can be affected by intrinsic or
external factors that cause random flaws. A simple web viewing system is not sufficient to
catch these defects, so continuous inspection of the printing is necessary in the modern
and efficient production environment. With a single touch, MATRIX PLUS automatically
STATISTICAL starts the comparison of the live print with the stored reference image. The entire print
repeat will be continuously inspected with pre-determined sensitivities and speed.
PRINT INSPECTION • The operator can set individual sensitivity for each type of defect according to the
quality requirements. Each time a defect is detected the system will acoustically warn
the operator displaying the relative image. The usual defects are ink splashes, print
starvation, streaks, misregistration, color variation, hazing, scumming, washout, and
foreign object contamination.

10
 SOLUTIONS FOR PA C K A G I N G

• During production, if the operator misses a defect because he was busy with other
duties, he can recall the defect gallery screen. Here we picture the last 12 detected
STATISTICAL defects. For each defect the system stores data relative to type, size, position and time.
• Defect maps are automatically generated for each printed roll. The defects are
PRINT INSPECTION represented with different shapes, sizes and colors according to the type and dimension.
The roll maps are stored in a data base for immediate or future review.

DEFECT ANALYSIS

• This software allows in-line inspection on 1D and 2D codes ensuring rapid intervention
by the operator when any of the Barcode are out of standard tolerances. The area camera
periodically verifies the Barcodes printed in different locations and the relative data are
displayed on an overlay table. An alarm (red light) indicates out of tolerance from the
BARCODE reference as set by the operator according to job requirement.
• Each Barcode is inspected with particular accuracy according to ISO 15416 and ISO
VERIFICATION 15420 to guarantee readability when the product is scanned by Barcode readers.
• The classification for each scanned code is displayed in real-time. No special settings
are required since the software automatically adapts itself to the codes direction, size
and type.

BARCODE VERIFICATION AND GRADE BARCODE SENSITIVITY ADJUSTMENT

11
 • Maintaining the color during the printing for an entire run is probably the most critical
task. In each printing method, colors can deteriorate/change due to: variation in printing
pressure, viscosity, temperature, homogeneity of the substrate, variation in printing
speed and ink transferring.
• The Δ-Color Monitoring performs a continuous comparison between the standard
CIE L*a*b* values, acquired during printing, with those approved and mastered at the
beginning of production.
Δ-COLOR • For each job the system allows up to 40 different camera positions for color measurement.
The positions can be set for measurement within the image or from dedicated color
MONITORING patches.
• The ΔE tolerance is set by the operator according to job requirement. Individual
tolerances can be set for each measuring point.
• An alarm indicates deviations from the reference values in ΔE. This gives the operator
advance warning to adjust color before it reaches levels that could compromise the print
quality.
• For every measurement, the color trend and the various deltas (Δe CIE Lab, Δe CMC, ΔL,
Δa, Δb) are represented on color space graphics.

COLOR
TOLERANCE
SENSITIVITY
ADJUSTMENT

DEDICATED • Certain substrates or particular inks and varnishes (transparent, UV, cold-seal) are
difficult to inspect with the standard illumination, therefore Grafikontrol designed special
ILLUMINATORS illumination methods that guarantee clear visualization of these difficult materials
FOR SPECIAL during the print run.
• Special illuminators can be supplied for specific purpose inspection or added to the
APPLICATIONS standard illuminators for selection as needed.

12
 SOLUTIONS FOR PA C K A G I N G

• The Interactive Register © “click & drag” is the revolutionary function invented by
INTERACTIVE Grafikontrol for CI flexo presses. Undoubtedly the best function that allows the pre-
registration of printing decks without dedicated marks. The function is mainly used
REGISTER© during a job start-up, with the press stopped, in order to minimize waste.
• This software allows the operator to interact with the image displayed on the screen. A
/ REGISTER snapshot is taken of the printed image which contains all the colors to be corrected. As
a reference, the operator can use the micro dots for the alignment of the plates (present
PRESETTING in most of the jobs) or any print detail for each specific color. By simply touching the
reference points, the system calculates the shift among the X-Y coordinates of all colors
FOR CI FLEXO and performs all the corrections in few seconds.
• In the presence of dedicated register marks, the system performs the pre-register
PRESSES automatically without stopping the press and without operator intervention. This
operation allows a further reduction of start-up waste.

INTERACTIVE
REGISTER©
“CLICK&DRAG”

• This feature is highly important when you are printing extensible substrates and the
length repetition of the product must be accurately controlled to avoid rejections during
PRINT REPEAT the post-press processes.
• The operator can set different tolerances according to type of substrate and product
MONITORING specifications. An instrument indicates the variations with respect to the preset value
and a synoptic signal is activated when the print length exceeds the tolerance.

13
INSTANTANEOUS
VISUALIZATION OF FRONT
AND BACK (COLD-SEAL) PRINTING

MATRIX C/S is a dual camera system that allows The combination of optics and lighting has allowed us
instantaneous display of the front and back of the print to obtain the best performance in terms of visualization
for verifying the register overlap. The equipment is of the transparent lacquers, varnishes and cold-seal
composed of two opposite digital monochrome matrix on any substrate. A special “image enhancement”
cameras (1,3 Megapixels) with fixed magnification feature improves image contrast on both sides of the
which move synchronously on 2 cross beams, web. The system instantly shows the image of the
controlled by a single motor. The system is equipped cold-seal superimposed and synchronized with the
with polarized optics with geometry designed on image of the front print for a precise evaluation of the
Grafikontrol specifications, particularly designed out-of-register of the cold-seal.
for the inspection of metallized substrates. The LED “Out of register alarm” - It is a dedicated software
illuminators used on the MATRIX C/S system belong to (optional) that allows you to warn the operator when
the fourth generation, more performing and efficient, the register between front (print) and back (cold-seal)
able to guarantee better light distribution on any exceeds the set tolerances.
substrate.

14
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

PRINT SIDE COLD-SEAL / COATING SIDE

FRONT AND BACK IMAGE SUPERIMPOSED MULTI-VIEW SCREEN

• Continuous measurement of the entire print repeat, detection of longitudinal and

transverse register variations.
• Manual and automatic preset of the camera in the positions chosen by the operator.
• Camera positioning through the use of icons on the multi-touch screen graphic interface.
• Internet connection for remote diagnostics.
• Real-time visualization of the front side (print), back side (cold-seal) and overlapping of
both.

15
SIMPLE&SMART WEB VIEWER

PARVIX, is equipped with a 1,3 Megapixel digital The powerful hardware and the new HD multi-touch
color camera that allows to display a 150x110mm operator interface guarantees high performance,
field of view on a 24” multi-touch monitor. The high- fast settings and quick operations. Intuitive graphics,
brightness optics equipped with 10X motorized zoom similar to tablets, make learning operations simple
combined with the newest generation of high efficiency and intuitive even for beginners.
LED illumination allow snapshots of the running web PARVIX acts as a simple web viewer but the modular
providing the operator with clear and dot-sharp images design offers the opportunity to configure the system
of all printing areas. The 10X motorized optic enables as the customer wants.
to display the printed images with magnification of the
details to dot level.

16
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

INTERACTIVE REGISTER (CLICK&DRAG) SCREEN

• “Full color” image processing on any type of substrate by using a digital RGB
matrix camera.
• Continuous scanning of the whole printing size, through data input of job
specifications, print repeat and web width.
• Up to 32 camera positions storing with possibility to differentiate zoom, iris, and
focus for each image.
• Camera positioning via icons on the multi-touch screen graphic interface.
• Manual and automatic camera preset in selected positions.
• Pre-settable zoom, iris and focus via multi-touch screen.
• Internet connection for remote assistance.
• The basic system can be expanded with Click&Drag Interactive Register©
revolutionary function for flexo machines that allows performing pre-registration
for all the printing deks without dedicated marks. The software allows the operator
to interact directly with what is displayed on the screen, which is a snapshot of
the image printed with all the colors to be corrected. The function is mainly used
during a job make-ready, with the machine stopped, so as to minimize waste.

17
100% PRINT INSPECTION.
THE GUARANTEE FOR TOTAL
QUALITY CONTROL

In roll-to-roll packaging printing the demand for defect The immediate warning, when a flaw is detected ensures
free product and tight regulations obligate printers to that the defective material is eliminated, optimizing
equip their presses with systems that can guarantee the process and avoiding claims. The modular
a total quality control. This avoids embarrassing architecture, combined with powerful hardware and
situations with your customers that can result in costly dedicated algorithms for image processing, make the
reprints or monetary credits. LYNEX PLUS is a 100% LYNEX PLUS a flexible and easy-to-use instrument
print inspection developed by Grafikontrol to assure for inspection on gravure, flexo, offset and digital
the total quality control during the printing process. presses. It is possible to set quality standards based
The continuous inspection of the entire print repeat, on customer needs and specifications. LYNEX PLUS
with programmable sensitivities, allows the automatic can operate as stand-alone module in multiple
detection of all print or substrate defects and a real- processes, as a print or substrate inspection device,
time evaluation of the production. or in combination with the MATRIX PLUS.

18
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION
LYNEX PLUS combines one or more 8K-pixel RGB linear cameras for an accurate
real-time inspection of the entire web width at production speeds exceeding 1000
HIGH SPEED AND m/min. The hardware of this system has been designed to also work with 4K-pixel
or bi-linear 8K-pixel cameras for applications on laminators, slitter machines,
HIGH RESOLUTION doctoring machines and narrow-web printing machines.
LINEAR CAMERAS The information from the cameras is processed through powerful hardware to
provide accurate and reliable image inspection. With an adequate configuration
it is possible to inspect the printed surface for the detection of defects up to 0.1
mm or lower.

INDIVIDUAL
DEFECT
SENSITIVITY
ADJUSTMENT

LYNEX PLUS provides as standard the “real-time” display of the entire print
REAL-TIME FULL repeat. Grafikontrol’s dedicated image processor allows to displays the live image
PRINT REPEAT of EVERY REPEAT as a full web viewer on a 32” or 55” UHD monitor. The operator
can analyze the print conditions on the whole web and immediately intervene as
DISPLAY needed. When a defect is detected, its location is highlighted on the screen.

“Easy and efficient” are the best terms to describe the new LYNEX PLUS operator
MODERN interface. Press operators will not struggle to learn how to use the system
functions.
MULTITASKING The gestures and actions are the same common ones used in smartphones and
USER INTERFACE tablets. LYNEX PLUS is operated through a standard 24” HD 16:9 multi-touch
screen. Operators can navigate from screen to screen by just touching or sliding
the image.

19
 SYSTEM FUNCTIONS

4 5

12
2
3

6 7 8 9 10 11

1 PRODUCTION DATA 7 COLOR DEVIATION

2 PRINT REPEAT MONITORING 8 DOCTOR BLADE/STREAKS

3 BARCODE VERIFICATION AND GRADE 9 INK SPOTS

4 Δ-COLOR MONITORING 10 INSECTS/FOREIGN MATERIAL

5 ROLL MAP 11 COLOR MISSING/DRYING

6 HAZING 12 SENSITIVITY SETTING

20
 SOLUTIONS FOR PA C K A G I N G

DIGITAL ZOOM DEFECTS GALLERY AND DEFECT DETAIL

• Auto-scan: this brand-new function performs the same job as a matrix camera,
allowing the operator to view the scanned areas with a pre-selected zoom
magnification.
• Digital Zoom: 6X digital zoom allows the operator to digitally zoom on certain
details over the entire print repeat by using the full print repeat monitor.
• Gallery of Defects: the chronological sequence of the defects and a scrolling
function provide an easy evaluation of the process.
• Different Sensitivity Levels: the operator can define the sensitivity for each
classification of defect according to the job specifications.
• Masking: undesired defects which cannot be removed from the printing, can be
completely masked to avoid constant alarms.
• Job Report & Statistics: for the total traceability of waste the system produces
a defect map for each printed roll showing in chronological order the defect, its
coordinates and a visual image for the reviewer.
• PDF/LIVE Master Comparison: this software, used during a job make-ready,
allows an easy and quick comparison of the live printing with the relative PDF
pre-press file to check for any differences. The in-line comparison is of big help
when printing different text languages or detecting engraving errors.
• Δ-Color Monitoring: through the live print repeat tab displayed on the multi-
touch screen the operator can easily select up to 24 points of measurement to
monitor the color trend. The ΔE values are continuously updated and visualized.
• Barcode verification: this function is distinguished by its ease of use. It
simultaneously finds and verifies all the Barcodes within the image (both 1D and
2D). The software automatically adapts itself to the code’s direction, size and
type and indicates if the code is out of tolerance from the reference. The software
grades the Barcodes according to ISO 15416 and ISO 15420 specifications. This
function requires that the LYNEX PLUS is supplied with a resolution 0,08 mm/
pixel.

STATISTICAL PRODUCTION DATA ∆-COLOR MONITORING

21
INSPECTION SYSTEM
CONFIGURATION FOR TRANSPARENT
VARNISHES AND COATING

LYNEX C/S is a 100% inspection system dedicated possible to obtain the best performance in terms of
to detecting defects related to coating processes visualization of the transparent lacquers, varnishes
for varnish, lacquers and cold-seal. Equipped with and cold-seal on any substrate. A special “image
4K-pixel monochromatic linear cameras, the system enhancement” feature improves image contrast on
allows the user to check the correct printability of both sides of the web.
varnish/lacquers and cold-seals, detect defects The LYNEX C/S can be integrated with the 100% LYNEX
in the substrate and categorize them according to PLUS inspection system installed on the print side,
the different types and create individual reports for improving the performance of “total inspection” (front
subsequent quality control. + back) and offering real-time control of the job.
The system is equipped with polarized optics designed Both sides of the web are displayed individually on
on Grafikontrol specifications, particularly designed 24 “multi-touch monitors and, at the same time, the
for the inspection of metallized materials. images for front and back side of the web are shown
The LED illuminators used on the LYNEX C/S system superimposed on a 32” or 55 “UHD monitor so as to
belong to the fourth generation, more performing and have information in real-time on the quality of the
efficient, able to guarantee better light distribution on job and on the front/back register. A special “image
any substrate. enhancement” feature improves image contrast on
The geometry of the optics and illuminators combined both sides of the web.
with the detection angles of the cameras made it

22
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

VIEWING OF FRONT AND COLD-SEAL SIDE

• Fixed pixel resolution: 0.2x0.2mm run&cross direction.

• Digital zoom.
• Black and white image processing on any type of substrate through the use of 4096 pixel
monochrome cameras.
• User-friendly graphics interface.
• Detection of defects by size and type.
• Sensitivity adjustment for each type of defect.
• Display of the defect map for each roll in process.
• Quality reports for each printed roll.
• Database containing 6 months of production.
• Connection to the company network for production management (optional).
• System can interface to the press using contacts to automatically control the waste devices.

23
INTEGRATED SOLUTION
FOR 100% PRINT
TOTAL QUALITY CONTROL

PROGREX PLUS is Grafikontrol’s solution to • MATRIX PLUS area camera for an accurate visua-
achieve high-quality standards. The combination lization of the details.
of the different technologies, linked to image The parallel operation allows control of the printing
processing algorithms, provides a complete and process from a single user interface. The interactive
simple instrument to support the operator in functions between the two systems make PROGREX
controlling the printing. The solution combines PLUS the most ergonomic inspection equipment on
two high-end technologies in one single system: the market today.
• LYNEX PLUS for the 100% inspection of the entire
web with full print repeat display.

24
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION
The software offered with MATRIX PLUS and LYNEX PLUS are integrated into the
SMART PROGREX PLUS for a complete quality assurance package. Intuitive and modern
INTEGRATION graphics are combined with the multi-touch screen reducing the time for system
set-up to only a few seconds.
FOR QUICK Print Inspection, Pre-Register, Barcode Verification, Δ-Color monitoring, and
PDF to Live Master Comparison, all are integrated into the system framework
OPERATIONS and can be immediately activated from a single operator screen.

PROGREX PLUS uses the capabilities of the LYNEX PLUS 100% inspection and
the MATRIX PLUS area cameras to give the printer the highest quality standard
possible. In combination, the following functions developed by Grafikontrol are
also available:
COMBINED • Click and View: touching any point on the 100% Print Repeat monitor drives
OPERATIONS the area camera to the coordinates and zooms the image with a programmed
magnification, speeding up the operation.
FOR BETTER • Double Inspection: while the LYNEX PLUS operates on the 100% of the web with
certain defect sensitivities you can set the MATRIX PLUS to higher sensitivity to
INSPECTION inspect critical points (examples: logos, color tones, register). The defects are
combined on the same roll map.
• Additional functions: while LYNEX PLUS operates on the 100% of the web,
MATRIX PLUS can simultaneously perform the verification of barcodes, color
variation and monitoring of the print repeat.

PROGREX PLUS provides two levels of waste management depending on

DEFECT TAGGING, customer requirements.
REMOVAL “Waste tagging” is the basic solution that automatically marks the waste portion
on the substrate during the printing. The system provides a trigger output that
AND WASTE can be used for any marking method selected by the customer such as flagging,
spray nozzle, or inkjet. In folding carton printing this function can automatically
MANAGEMENT activate the waste gate.

VIEW OF THE
ENTIRE PRINT REPEAT
IN REAL-TIME

25
WASTE MANAGEMENT
& DEFECT REMOVAL

EASY-TRACKER is the newest system for the coding

and traceability of defects during the entire production
process (printing, lamination, slitting).
The use of innovative hardware and software, entirely
developed by Grafikontrol, allows an accurate removal
of defects in the slitting phase.
In the first working process of the roll a variable
code (sync-code) is printed with an INK-JET marker
at regular intervals on the roll web edge; the sync-
code contains the printed roll data: job number, roll
number and footage.
Whenever a defect is detected by the 100% inspection
system (PROGREX PLUS / LYNEX PLUS) its position
on the web length is immediately paired with the
closest sync-code. At the end of each produced roll
the system generates a data-report containing all the
detected defects and the sync-codes associated to
them. The purpose of EASY-TRACKER is to track all
the defects detected during the different processes
(printing, coating lamination, etc.) and save them in a
data file. An editing station allows the quality control
to discriminate and filtering the different typologies
of defects according to customers’ requirements
(criteria). After the editing phase, the roll moves to the
final machining process where the selected defects
will be removed.
With this innovative system you get:
a) Increase in production speed.
b) Increased efficiency of the entire process thanks
to the automatic stops of the slitter, facilitating the
elimination of defects.
c) Guarantee of a finished product free from defects,
avoiding complaints from end customers.

26
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

PRINTING
PROCESS
DEFECTS ARE PAIRED
WITH SYNC CODES

SLITTING
PROCESS
DEFECTS ARE REMOVED
FROM THE ROLL. SLITTER
STOPS AUTOMATICALLY
ON THE SYNC CODE
PAIRED WITH THE DEFECT

• Size, shape and pattern of the sync-code are programmable.

• The size of one sync-code is 2-2.5 mm by 35-40 mm (w x h) and contains Job
name, Roll Number and Meterage.
• The Ink Jet nozzle (to print the sync-code) is installed on a motorized bar and on
the same bar is installed a sync camera that:
a) automatically detects the web edge (for auto alignment)
b) guarantees print repeatability and verifies the readability of the sync-code
just printed.
• The sync-camera reads and transmits the sync-code information to the system in
real-time for an accurate paring of the detected defects with the roll footage.
• The frequency in printing the sync-code is programmable (normally is one sync-
code every one or two print repeats).
• When a roll terminates the printing (or lamination) phase a label printer (supplied
with the system) generates a label on which a univocal barcode is printed,
containing all roll data.
• System is supplied with a dedicated editing SW to filter the undesired defects,
only the selected ones will be removed by automatically stopping the slitter on the
sync-code paired with the defect.

27
IN-LINE SPECTRAL
COLOR MEASUREMENT

During printing, the most common causes of color measurement, allows precise color evaluation in real-
management issues arise from several factors: a time so that the operator can take immediate action to
doctor blade that wears, a plate or anilox that need to be correct the color trend before it goes out of tolerance.
replaced, variation in viscosity or ink concentration etc. Using an exclusive software, CHROMALAB analyzes the
When any of these components change over time, it will spectral variations in color measured on the print and
ultimately affect the color. It is well known that brand makes the data available for a possible connection with
owners adamantly want harmonization of their colors an ink dosing system in order to be able to perform a
across all substrates, applications and geographies, to correction of the ink formulation. CHROMALAB’s in-line
communicate brand equity to consumers worldwide. and continuous measurements provide more detailed
For this reason, accurate color measurement during and accurate color monitoring allowing for reduced
production is extremely important to ensure consistent, start-up waste and reaching customer color standards
high-quality printing. The CHROMALAB, in-line color much faster.

28
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

• Provides real-time color measurements: spectral curves, ΔE, L*a*b* values,

Density, Dot Gain.
• Uses a motorized traverse for automatic positioning on the color bars or directly
on selected areas of the image.
• The spectrophotometric sensor is aligned with an area camera to help the
operator find the image/color patches to measure.
• The system provides an accurate match with all major brands of handheld
devices.
• Measures up to 16 colors across the web; color measurement can be made
on color patches (automatic pattern recognition) or directly from the printed
image on any type of substrate.
• CHROMALAB has been designed to fit on flexo and gravure presses.
• Provides on line, absolute color values which are correlated with color
measurements made off-line by the press quality assurance departments and/
or by the end customers.
• Charts & Graphs of color trends are stored for future evaluation and can be
seen in real-time from remote location or tablets.
• The system provides data for a possible connection with an ink dosing system
to be able to correct the formulation.

DENSITY

MAIN OPERATOR SCREEN

L*A*B* GRAPH

L*A*B* VALUES HISTOGRAM TRENDS

29
COLOR REGISTER CONTROL
SYSTEM FOR PACKAGING
ROTOGRAVURE PRESSES

The CR33 - CR34 register control systems guarantee flexo or offset). It can function on all registered printing
the highest accuracy and reduction of waste during units or as single control for a downstream station.
all phases of production: make-readies, acceleration, The systems are designed to fit on new or existing
and splices for both mechanical and e-shaft presses. presses and are adapted for in-line or tandem
The superior electronic technologies and dedicated configuration presses. The fiber optics scanners are
software algorithms guarantee steady register between specially designed using high sensitivity RGB sensors
the colors for the entire press run resulting in maximum which automatically adapt the amplification to detect
operator and press efficiency. CR33 and CR34 can be very low contrast colors on any kind of substrate.
easily adapted to different printing processes (gravure,

30
 SOLUTIONS FOR PA C K A G I N G

SYSTEM CONFIGURATION

GAUSSIAN GRAPHS OF REGISTER ACCURACY REGISTER TREND

SET UP SCREEN MAIN OPERATOR SCREEN

• The hardware design allows the system to be adapted to the • The user-friendly touch-screen interface utilizes intuitive
customer requirements: graphics and gestures to assure easy learning, fast set-ups and
› The CR33 comes with a cabinet to hold all the required simple adjustments during the job run.
electronic components in one enclosure • Make-readies will be quicker with the job storage database,
› The CR34 is supplied as an integrated unit for new e-shaft all the job parameter settings, such as press configuration,
presses compensator preset and register tolerance can be saved and
• The motorized scanners (designed for ex-proof areas) along recalled.
with the “automatic-pattern-recognition”, “mark-auto-search” • Specially designed software allows the system to control the
and “mark-auto-centering” allow a fully automatic start-up insetting of pre-printed webs or for registration with downstream
without any operator intervention (with an initial scanner position processes.
tolerance of ± 7 mm). • When the register error exceeds the set threshold value, a visual
• The LED light source guarantees more than 100.000 hours of life and audible alarm is activated and a waste output signal is
(11 years). The 1 mm light spot allows mark size to be reduced to provided to mark or reject the product.
3 by 3 mm. • The system provides various data output possibilities for
• Various mark patterns and shapes can be programmed or diagnostics or reporting such as: real-time register trend
selected from the library so that existing cylinders can be used. streaming, out of tolerance trigger signaling, or spooling to an
• The “auto-preset” function, developed for electrical shaft external printer port.
presses, performs the cylinder phase presetting and guarantees • The system is configured for remote support through a dedicated
completely automatic register start-ups. and secure VPN connection.
• Real-time charts display the error trend and the production
statistics. The system also provides an interface to the company
network or external users for data sharing.

31
 n Cor
ina

India

SALES AGENCIES SALES AGENCIES

AND LOCAL SERVICE

WWW.GRAFIKONTROL.IT

GRAFIKONTROL SPA GRAFIKONTROL NORTH AMERICA

Via Ludovico D’Aragona, 7 Slate Hill Business Center
P - rev.08.00.EN

Milano, 20132 3907 Hartzdale Drive, Suite 706

Italia Camp Hill, Pennsylvania 17011
Ph. +39 02 2100951 Ph. +1 717-850-9700
sales@grafikontrol.it sales@grafikontrol.com