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Software für Qualitätsmanagement

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Inspektions- und Testsysteme für organische und gedruckte Elektronik

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100% absolute color measurement for printed products: Reduce make-ready times and decrease material consumption

Colors significantly define the face of a brand. Globally active brand owners, therefore, only allow very small color tolerances. ColorSTAR, a new module for the 100% print inspection system PrintSTAR from ISRA VISION, enables perfect color measurement – anytime and anywhere, ensuring that color specifications are adhered to. Printers benefit from a smooth, error-free production process and can acquire new clients.

 In the packaging sector, printing with high color consistency is a significant quality criterion. Flexible packaging, body care products, labels, hygienic films, aluminum packaging for medication and food, packaging for liquids, security printing, and much more are all printed with brand slogans or safety information. A brand is often defined to a large extent by its color profile, which is why global brands only allow very small color tolerances. Printers require a reliable tool to check the color consistency during production and within the make-ready time.

The ColorSTAR module provides the PrintSTAR inspection system with absolute color measurement data. This feature enables continuous monitoring of the color accuracy of printed products on printing machines, without interrupting production. Color line scan cameras are combined with a spectrophotometer to enable continuous measurement and monitoring of absolute color values (L*a*b*) and color density. These measurements can be performed and repeated at any point in the process. As soon as printing commences, the measured color values are compared to the target specifications. The operator can adjust the color without having to stop the printing machine. ISRA technology allows the taking of real-time measurements, thereby reducing make-ready times by up to 60% and lowering material consumption. The system guarantees color consistency throughout the entire print batch in line with the brand owner’s specifications. Manual measurements  are no longer necessary.

Color deviations are prevented across the entire web width, and the customer’s expectations are met. Any deviations that exceed a fully-adjustable limit value trigger an alarm or other actions. Rejects and waste products caused by color deviations are now a thing of the past. The system, therefore, makes a valuable contribution to sustainable production.

The solution is suitable for all substrates – even transparent ones – and operates at any printing speed. Measurement positions are tracked automatically and continuously for all materials, including thin and stretchable ones, without any additional equipment. The color consistency must be documented for the brand owners. With ColorSTAR, complete and automatic documentation of every roll is guaranteed. This enables efficient process and quality control. Deviations between target and measured values are recorded and displayed in an L*a*b* diagram.

Another distinct feature is scalability. Printers can use the solution that is tailored precisely to their requirements. PrintSTAR can be equipped with the ColorWATCH option – the perfect introductory solution for comparing colors with a master. If requirements increase, it is possible to upgrade to the ColorSTAR option at any time, enabling absolute color measurement at all times. Thanks to inline color measurement and well-documented color consistency, printers will be able to gain new customers in the demanding packaging sector.

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Turkish can manufacturer ARKIN METAL relies on 100% quality control from ISRA VISION

Increased process efficiency for flawlessly decorated metal cans
Metal cans are subject to high quality requirements. The Turkish manufacturer ARKIN METAL has a modern production line with a high-performance metal decorating press for manufacturing cans. The high quality of the products is monitored using DecoSTAR from ISRA VISION. This state-of-the-art solution for 100% print inspection from the world’s leading provider of surface inspection systems ensures that the high metal decoration requirements are met in the best possible way. The solution has already proved successful in operation.

ARKIN METAL produces decorated metal sheets, which are subsequently processed to form cans for oil, all kinds of metal packaging, end use and other food packaging as well as non-food applications. A KBA MetalStar 2 – one of the fastest metal decorating presses in the world – has been used for several years. It allows some 8,500 metal sheets to be decorated per hour. ARKIN’s customers are filling companies with the very highest quality standards for the decorated metal packaging.

Before this press was installed and when production speeds were not yet so high, the few defects could be found and eliminated manually. However, the high speed of the press made it ever more difficult for ARKIN’s employees to monitor production and detect problems. The number of color applications has also risen. As a result, ARKIN METAL began to consider an inspection system for its metal decorating press. ISRA VISION quickly emerged as the preferred provider of inspection solutions, as its systems are particularly reliable and stable.

The user’s objectives with regard to the inspection system were improving quality, reducing waste and thus increasing the amount of material that can be sold. In addition, the company aimed to enhance quality management and boost the expertise of both customers and operators.

Inspection solution with crucial benefits
Deploying the DecoSTAR inline inspection system offers crucial benefits for the user: With highly precise measurement and motion compensation for the metal sheets, the unique, bespoke solution ensures perfect print quality and metal decorations. Once the inspection system was installed, serial defects were successfully categorized and then eliminated. After just a short time, the operator could no longer imagine running the press without an inspection system.

The inspection system uses an 8K color camera and ensures 100% inspection of up to 10,000 sheets per hour, allowing reliable detection of defects as small as 0.03 mm2. These defects include contrast differences, dust, dirt and covered lines at various print speeds. The system also monitors the decorated sheets for possible color deviations.

Commissioning in a matter of days
The Turkish ISRA VISION team supported the operator on site, providing instruction and training on how to use the inspection system. Due to the system’s short installation time and intuitive nature, it was put into operation in just a few days. The inspection solution has now been in successful use for four years. Because all relevant defects are detected, ARKIN METAL has achieved a more stable level of production on its line. Even at high speeds, the production line is noticeably easier to monitor. Production waste has been reduced significantly as a result of early defect recognition. As possible problems are solved before products are delivered to the customer, complaints are prevented.

Reproducible quality at maximum speeds
The data collected by the inspection system is systematically analysed and used, with the manufacturer using feedback from defective sheets to optimize production. The sizes of all the defects in all produced metal sheets are recorded, making documentation easier and aiding communication with the manufacturer’s customers. All in all, the inspection system allows the company to supply the produced goods to its customers without any problems, boosting customer satisfaction.

In the manufacturer’s view, the inspection solution’s ability to differentiate between all defects that can occur during decoration makes ISRA a technological market leader in the field of inspection technology. The user benefits from reproducible quality at the highest production speeds. The company’s production has now been accurate, reliable and stable for a number of years and many serial defects have been eliminated – thanks in no small part to the inspection system. The DecoSTAR inspection solution significantly increases the efficiency of the production process for decorated metal packaging.

Onur Tecim, Production Manager at ARKIN METAL, is highly satisfied with the inspection system. “We could achieve a more stable production within the printing process due to the ISRA System. As a result of the defect detection which leads to an intervention of our operators at an early stage, the number of scrapped material could be reduced significantly. Also we could reduce customer complaints and meet our customer quality expectations better.”


With the automated print inspection system from ISRA VISION, all quality requirements can be met. The user benefits from 100% inspected decorated products and the very highest level of process efficiency, strengthens their company’s market position and secures a competitive advantage. In addition, the system conserves resources and makes an important contribution to the sustainability of production. As a result of its positive experiences, ARKIN METAL is now planning to install an inspection system in its coating line.

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Perfectly printed corrugated board thanks to CartonSTAR: Increased quality with 100% inline print inspection

ISRA VISION, the world’s leading provider of surface inspection systems, offers cutting-edge technology for continuous quality and process control of the printed image on corrugated board surfaces with its 100% inline inspection system CartonSTAR. The system, which is used in both “post-print” and “pre-print” stages of production, reliably differentiates between quality-relevant defects and inhomogeneous surfaces.

Never before has there been as much emphasis on quality and consistency of printed corrugated board. Due to these increasing demands, suppliers of state-of-the-art packaging solutions need to provide precisely documented quality.  With inspection during the printing process, the printer can depend on continuous, automatic visibility of the printed image and material quality. Using inspection systems significantly reduces the necessity for manual quality checks by dramatically reducing waste.  Other benefits include the reduction of costly reprinting and the ability to run the press at higher speeds for improved productivity.  The inspection data can even be used to investigate the causes of defects.

Meeting 100% of customer demands 100%
CartonSTAR is an inline inspection system designed to meet the stringent quality requirements of the competitive corrugated industry. It detects all relevant defects on the printed surface. Thanks to its enhanced functionality, the system can reliably differentiate between typical surface structures and defects, all in real time, even at full production speeds. As such, the system is capable of “disregarding” the inhomogeneous surface structure of the corrugated board while reliably locating and categorizing anomalies in the print, including color deviations.  

CartonSTAR utilizes sophisticated “defect classifiers” to precisely identify abnormalities independent of substrate imperfections resulting in defect free product for your most demanding customers.  Since the system is able to focus on actual defects, it helps to achieve higher production throughputs.

Adaptable to all applications
The highly configurable CartonSTAR system can be tailored to accommodate the most challenging printing tasks. Even holograms can be inspected. With its compact design, the system easily integrates into most printing presses and die-cutters. ISRA LED lighting is highly efficient and durable, designed to run for many years without any maintenance. All system components are built to withstand the toughest environmental conditions of corrugated board production.

CartonSTAR can provide communication for defective sheet ejection, conserving resources and saving costs in the production process while also giving the operator peace of mind that only defect-free product is on its way to customers. In addition, the system reporting tool registers all incidents and presents them in a clear, concise defect report for distribution to the quality department and the customer.

100% inspection with CartonSTAR increases product quality while reducing production costs.  Moreover, the solution provides the means to monitor your printing process and quickly alert the operator to correct problems that often lead to unnecessary production waste. The savings provided by 100% inspection strengthens your company’s reputation for quality products and secures a competitive advantage.

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Über uns


Die ISRA VISION AG ist samt Tochtergesellschaften Weltmarktführer für Oberflächeninspektionssysteme. Zudem zählt das Unternehmen zu den global führenden Anbietern im Bereich Industrielle Bildverarbeitung (Machine Vision) mit Spezialisierung im Bereich 3D Systeme zur Roboterführung, Formerkennung und -vermessung.

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