Press manufacturer Nilpeter has jointly developed a vision inspection system with Austrian automated technology manufacturer B&R that the companies claim reduces waste, improves quality, and minimises labour. Reflecting the Nilpeter’s broader strategy for ‘The Future of Flexo’.  

The technology is a high-speed register system that maintains colour registration with precision, during both acceleration and deceleration, even when handling ultra-flexible materials often used on the Nilpeter FA-26 and other FA-Line machines.

Nilpeter states the system sets a new standard for maintaining colour registration accuracy, with its microsecond synchronisation between motion and vision, ensuring consistent print quality. This is due to B&R’s integrated solution, whereby its camera consistently captures and processes images in real time, accurately detecting and adjusting for any variations in print alignment.

As a component of the vision solution, B&R’s smart sensor contributes to waste reduction, quality enhancement, and labour minimisation. The sensor, with its multi-colour flash and integrated processing, facilitates precise colour registration by quickly analysing images and making real-time adjustments, according to B&R.

Nilpeter said a job-reload feature results in ‘perfect’ registration from the start of each job. The feature is supported by a job database that defines the criteria for each task, reducing waste and ensuring consistent high quality on all prints. It is claimed that this has a positive impact on CO2 emissions.

The vision solution also includes fallback systems to ensure that the registration mark is detected regardless of colour combinations. Additionally, the system is fully integrated with data collection capabilities, enabling Nilpeter to provide quality badge reports. This allows customers to make informed decisions based on accurate, reliable data.

‘We envision a future where machines are either completely self-contained or operated by a single person managing multiple units,’ said Carsten Clemensen, chief technology officer at Nilpeter. ‘This approach not only addresses the industry’s critical skills shortage, but also guarantees improved, consistent quality with every print.’

Jacob Buhl, regional vision expert at B&R, concluded, ‘The groundbreaking vision system exemplifies B&R’s commitment to seamlessly integrating vision solutions into machine operations, driving innovation and redefining industry standards. Together with Nilpeter, we’re not just advancing printing technology – we’re revolutionising it.’