Delivering top quality on demand

A high spec slitter rewinder with 100% inspection supplied by AB Graphic is proving instrumental in meeting the stringent demands of the pharmaceutical industry

AB Graphic International has installed a 13” (330mm) wide flytec 2010 slitter inspection rewinder at New York-based Gintzler Graphics. The full specification machine will be used to convert and inspect high quality labels for the pharmaceutical market.

“We made the decision to acquire the flytec 2010 because we wanted to enhance the level of service to our critical care clients,” explains CEO Bryan Scheible.

“The market we serve demands perfection and we wanted the latest technology. We needed a platform that could interface with Domino Ink Jet for serialisation during final inspection. A multi-plant facility, we were looking for a vendor that could service all our facilities and offer remote diagnostics.”

Key elements of the flytec 2010 at Gintzler Graphics include bi-directional unwind/rewind and fleyeVision 100% print face inspection equipped with 4096 pixel, greyscale camera capable of detecting defects to a minimum size of .0000465 square inches (0.03 square mm) at speeds up to 22.2f/pm (120m/min.) Labels with static and dynamic 1D and 2D bar codes can be checked to ANSI standards. The system permits labels to be compared against prepress created PDF files and taught to read the ‘golden image’ data.


Final inspection

“This equipment is used to perform the final inspection of the label prior to shipment and has automated the required leader and trailer function needed for each roll of labels shipped,” continues Scheible. “The comparative vision system on the flytec proved superior to its competitors and the software was customised to generate image capturing documentation for client reporting purposes. We were able to work closely with AB Graphic International who set up a full integration team to ensure the machine functions met our unique requirements.”

Equipped with pharma control module the flytec 2010 is designed to meet US legislative requirements for pharmaceutical labels, records all operator access and parameters carried out per job and produces all validation documents including IQ, OQ and PQ. Any defect found is recorded in the extended protocol software with photographs to enable subsequent static evaluation.

“This equipment is built to withstand the normal wear and tear of daily production and can interface with shop floor management systems,”says Scheible. “Throughput speeds are consistent and the accuracy at which the flytec detects nonconforming material is superior to other equipment tested. This enables us to deliver a better quality product.

“Our products supply high speed label application lines where label position to the liner edge is ultra-critical. The slitter assembly maintains exact positioning using ultrasonic label edge guide feeding data to the slitter servo to maintain the slitting parameters. This feature has allowed us to keep tighter tolerances on our label to liner edge requirements, reducing in process adjustments by our  customers. We are always looking for new technology to improve our process and the flytec has allowed us to exceed expectations; it greatly supports our zero defect initiative.”

“Bi-directional operation means that every defect can be checked twice by moving the web backward and forward,” comments Michael Leidgschwendner, managing director of AB Graphic International. “The first allows the operator to check if the defect can be replaced and/or make a repair and the second enables re-inspection to free. Multi-lane, bi-directional operation can  ensure the subsequent operation is error be carried out simultaneously with slitting and inkjet printing for numbering as the machine is equipped with an accumulator that makes it possible to combine these and further finishing steps in one operation. Up to eight ink jet printing heads can be independently controlled.”

The flyCut slitting control unit supplied to Gintzler Graphics includes a camera that checks web edge matrix movement and controls the unit to prevent inadvertent damage to labels. A label dispenser unit  designed to remove labels from the start or end of the roll creates a blank web to ensure all remaining labels have been inspected.

“This is the third system we have supplied for the label converting operation at Gintzler Graphics concludes Leidgschwendner. “The first was a flytec 150 for integration with an inkjet printer and the  second and third include the flytec 2010 model and an HSR slitter/rewinder destined for the company’s Texas facility.”

Gintzler Graphics produces labels, tags, paperboard packaging and speciality converting for a wide range of industries using both traditional and digital label printing processes. Custom effects include foil, screen and embossing.

AB Graphic International

T: +1 909 230 6640