The future of flexo

Flexo printing leader Nilpeter and B&R have jointly developed a revolutionary vision system that reduces waste, improves quality and minimizes labor. It sets a new standard for maintaining color registration accuracy, even with ultra-flexible materials. The system's microsecond synchronization between motion and vision ensures consistent print quality, making it unique in the marketplace. Nilpeter’s commitment to the new vision system reflects its broader strategy for the future of flexo printing.

B&R and Nilpeter have been working together for a considerable period, particularly in their research and development departments, to explore advancements in printing technology.

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

The precision of the vision solution is due to B&R’s integrated solution, which ensures microsecond synchronization between motion and vision. The camera continuously captures and processes images in real time, accurately detecting and adjusting for any variations in print alignment, thus ensuring consistent print quality.

As a component of the vision solution, B&R’s smart sensor contributes to waste reduction, quality enhancement, and labor minimization in printing. The sensor, with its multi-color flash and integrated processing, facilitates precise color registration by quickly analyzing images and making real-time adjustments.

The job-reload feature of the vision solution ensures perfect registration from the start of each job. This feature is supported by a comprehensive job database that defines the specific criteria for each task, reducing waste and ensuring consistent high quality on all prints. This benefits the company's bottom line and has a positive impact on CO₂ emissions, in line with broader environmental sustainability goals.

The vision solution also includes fallback systems to ensure that the registration mark is detected regardless of color 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.

Nilpeter's commitment to the vision system reflects Nilpeter’s broader strategy for "The Future of Flexo".

"We envision a future where machines are either completely self-contained or operated by a single person managing multiple units," says Carsten Clemensen, Chief Technology Officer at Nilpeter. "This approach not only addresses the industry's critical skills shortage, but also guarantees improved, consistent quality for every print, while drastically reducing waste and helping the environment."

Jacob Buhl, regional vision expert sums it up: "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 revolutionizing it.”