Quality
is one of the biggest differentiators in the packaging industry. Other factors
matter too of course – cost efficiency, sustainability, lead times – but
ultimately if packaging fails the quality test, it can jeopardize a whole run,
and a customer relationship with it. In some sectors – pharmaceuticals for
example – packaging faults can have even more significant consequences.
But
how can manufacturers maintain quality control in an increasingly competitive
environment where margins are being squeezed and short runs with short lead
times are becoming more common? In this environment, most companies cannot
afford the luxury of Quality Control personnel carefully checking their packing
process. The onus is now on the manufacturer to provide completely fault-free
packaging in short lead times.
“Achieving
zero-fault packaging is a key goal for all our customers,” said Pierre
Binggeli, Product Marketing Director Business Unit Sheet-Fed Folder-Gluers at Bobst.
“They want to ensure perfect quality production and timely detection of any
errors within the production chain. They need a system they can rely on to
identify issues and eliminate sources of errors, leading to quality consistency
and client satisfaction.”
Bobst
was the first company to introduce a fully integrated in-line quality control
system on a folder-gluer back in 2011 with the first generation AccuCheck,
providing a seamless progression, with no additional quality control step
required in the process. This solution inspects carton blanks for defects as
they enter the Bobst folder-gluer. In the years since, AccuCheck has become a
benchmark solution in the industry and a must-have for Bobst’s pharmaceutical
customers in particular.
“It
has been a tremendous success with our customers in the pharmaceutical sector,”
said Mr Binggeli. “For them, it provides real peace of mind – 100% quality-controlled
production, ensuring compliance with industry standards, reducing the risk of
censure and penalties.”
Combining
zero-fault packaging and high speed: the new AccuCheck
Bobst has now developed an evolved version of its quality control system. The new AccuCheck
is compatible with the latest generation of MasterFold 75 / 110 or ExpertFold
50 / 80 / 110 machines. It carefully checks carton blanks for defects and
guarantees complete quality consistency at speeds up to 500 m/min, or 140,000
boxes an hour. That makes it the fastest in-line quality control machine, and
allows the machine to run full speed with AccuBraille. The latter gives
manufacturers the ability to emboss Braille onto all four panels of the carton,
even across the running direction.
Based
on the 30-year experience of Bobst's Registron technology, AccuCheck is a
highly flexible solution that allows users to inspect different box areas
according to the manufacturer’s – or their client’s – quality criteria, while
remaining easy and quick to operate. It enables full PDF management, with a PDF
function pack consisting of conformity check and reference control, which are
vital features in the pharmaceutical industry.
Other
new features include smart text identification, which is driven by machine
learning algorithm, as well as a reporting system that can be adapted to client
validation targets and is available through a web browser. AccuCheck is also
equipped with a dust removal device, which removes over 90% of dust particles
to avoid unnecessary default detection.
Comprehensive
inspection of the smallest imperfections
Inspection
capabilities of AccuCheck are extremely comprehensive and include accurate
color measurement and text inspection, detecting any print defects such as
missing print, text errors, code defaults and color variations. It also enables
complete analysis of the substrate integrity, preventing damages, dust (with
the dust removal device), oil or any external elements on the cartons.
Inter-processes
register variations (print, cut, foil, emboss) are measured precisely thanks to
our unique patented lighting system, and all embellishment processes such as
foil, varnish and emboss are closely inspected. It inspects 100% of varnished,
metalized and embossed blanks.
Defective
boxes – including any with splashes, spots, scratches or stripes – are ejected
automatically, with 100% quality-controlled production.
The
folding-gluing line is also easy to use. The new AccuCheck is equipped with the
HMI Sphere, which provides several operating modes for customized settings.
This feature is becoming standard on new Bobst machines. Inspection parameters
can be saved and recalled, with repeat orders set within seconds. Access rights
can be set for different users.
“Bobst
was the first folder-gluer manufacturer to offer this kind of quality control
device. With the new AccuCheck, we have taken automated quality control to the
next level,” said Mr Binggeli. “Combined with AccuBraille, we have a completely
integrated solution, which is unique in the industry. So far, this has mainly
served those working in the pharmaceutical industry – the full PDF management,
text inspection and reporting in particular suit this sector. But the new AccuCheck
can also be configured to suit other industry segments, with different speeds
and inspection needs that will serve the food and other industries equally
well.”
So,
zero-fault packaging is indeed a reality – and one that is rapidly becoming a
benchmark across multiple industries as Bobst continues to innovate.
