SOLUTIONS FOR WEB OFFSET

TOTAL QUALITY CONTROL AT 360°

 TQC360, A NEW CONCEPT
FOR DEFECT-FREE PRODUCTION
AND WORKFLOW MANAGEMENT

TQC-360° is the newest modular platform for Grafikontrol’s products.

It has been developed to give printers a complete solution for quality
assurance. With the TQC-360° concept, Grafikontrol offers a full range of
quality control to the printing and converting industry through production,
application, and processes and services. Our “all around” approach to
the customer combines high performing products and excellent service.

The TQC-360° products integrate into any web application. Customers

benefit from the modular design which allows them to start with the
features they need and upgrade at any time.

The components that make up the TQC-360° line can satisfy any customer
need. They can operate separately or together through a single operator
interface if desired. Tailor made solutions can be designed to fit non-
standard applications.

INSPIRED BY TECHNOLOGY
Grafikontrol has been recognized as worldwide leading manufacturer of
high performance equipment for the graphic industry for more than 45
years. We marry the best of high-tech components with the essence of
Italian engineering to manufacture best of industry products with a heart
“Made in Italy”.

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 SOLUTIONS FOR WEB OFFSET

PRODUCTS
• COLOR REGISTER
CONTROL WITH
MICROMARKS
• CUT-OFF AND SIDELAY
REGISTER CONTROL
• SPECTRO-DENSITOMETRIC
CLOSED LOOP COLOR
• “PAPER MONITORING”
WEB SURFACE ANALYSIS
AND DEFECT INSPECTION
• 100% PRINT INSPECTION
SYSTEM

APPLICATIONS
• COMMERCIAL PRESSES
• NEWSPAPER
• METAL PRINTING
• LIQUID PACKAGING
• FOLDING CARTON

PROCESSES

SERVICES • OFFSET
• DIGITAL
• REMOTE CONNECTION
& ASSISTANCE
• LOCAL SERVICE
• ANNUAL SERVICE
CONTRACTS
• 15 YEARS SPARE PARTS
AVAILABILITY

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CR25-CR26 COLOR REGISTER CONTROL page 6
CR25
The CR25 register control system has been developed using advanced electronic
technologies, such as high-speed matrix video cameras, specially made for the
purpose. These have made it possible to enormously reduce the space occupied by
the register marks (micromarks) for automatic control of circumferential and lateral
color register on web-offset presses in commercial and newspaper printing.

CR26
The cameras can be positioned, on request, between the last printing unit and the
drier, in order to ensure immediate response to variations in register and thus
further reduce the number of waste copies. The cameras read the marks on free
paper, unsupported by a roller, with a tolerance of oscillations in the web of ± 7 mm.

CR25TPLT CUT-OFF AND SIDELAY REGISTER CONTROL page 8

The CR25TPLT longitudinal and sidelay register control system for cutting and
folding has been developed using advanced electronic technologies, such as
high-speed matrix video cameras, specially made for the purpose. These have
made it possible to enormously reduce the space occupied by the register marks
(micromarks).

COLORSCAN MARKLESS CLOSED-LOOP COLOR CONTROL, page 10

WITH SPECTROPHOTOMETRIC ANALYSIS
In recent years printers have required their color control systems to reduce space to
save money. COLORSCAN has done this by eliminating the color bars.
The COLORSCAN system measures the optical density and L*a*b* values of the
colors on live production in ‘real time’, analyzing each sector across the web by
means of a mobile camera placed after the last printing unit.
The system automatically adjusts and maintains the color values by acting on the
ink keys and eventually on the inking roller speed.

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 SOLUTIONS FOR WEB OFFSET

PM3 WEB DEFECTS DETECTION page 12

Paper is more and more a critical factor in the printing process. The continuous
push for higher productivity means that web breaks, paper waste and monetary
claims due to web quality, are key factors in reaching profitability goals.
Modern wide presses and high production speeds require more efficient and reliable
systems to detect paper defects and to identify reasons for web breaks.
The PM3 system provides a control of the paper from the reel-stand to the press
delivery, to continuously check the paper quality and allow the operator to distinguish
web breaks due to the web quality from those due to press settings.

100% PRINT INSPECTION page 14

The demand for total print control is satisfied by our innovative 100% inspection
system. The LYNEX assures the control of the entire print repeat reporting and
storing every defect detected during the production. The system provides this data in
roll maps and generates production reports for subsequent analysis and workflow
use.
• Real time process analysis, the system operates at web speed up to 1000m/min with clear
discrimination of defect by size and type
• 4 K-pixel linear cameras for defect detection on any type of substrate and web width
• Job reports & Waste management
• Integration to the plant network for the production data management
• The PDF/LIVE Master comparison Software allows an easy and quick verification of the
make-ready live printing with the relative pre-press file

TECHNICAL DATA CR25-CR26 • CR25TPLT • COLORSCAN • PM3 • LYNEX page 18

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CR25-CR26
COLOR REGISTER CONTROL
WITH MICROMARKS

TECHNICAL FEATURES
• CR25 register control system uses specially made high-speed matrix video
cameras, which make it possible to reduce the register marks (MicroMarks) in very
small spaces (7 x 7 mm).
• Multiprocessor units with DSP (Digital Signal Processing) Technology.
• Cameras can capture 200 images per second, and the marks are read on each
cylinder revolution.
• Speed of operation from 15 to 1500 m/min.
• MicroMarks can be located anywhere on the printed web. They are not sensitive to
print conditions and can therefore always be identified by the cameras.
• Error sensitivity: 0.01 mm.
• Completely automatic register mark search and lock on.
• LED light sources, with a lifetime of over 100,000 hours (11 years).
• When register errors exceed the preset value, an alarm and the waste ejector can
be activated automatically.
• The system is configured for remote support through a dedicated VPN connection.

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 SOLUTIONS FOR WEB OFFSET

Register control with cameras placed before the dryer

CR26 On request, cameras can be positioned between the last printing unit and the
drier in order to ensure immediate response to variations in register, and thus
further reducing the number of waste copies.

Sidelay register control of the main web

CR25WG – CR26WG It enables centering the print under the slitters by interfacing with the web guide,
in order to ensure correct cutting into ribbons.

Fan-Out control
Automatic control of width variations in the printed web and skew of color print
CR25FO register. This can be supplied either separately or integrated in the color register
control.

MAIN OPERATOR SCREEN, FAN-OUT CONTROL SCREEN MAIN OPERATOR SCREEN,

NEWSPAPER PRESS COMMERCIAL PRESS
CONFIGURATION CONFIGURATION

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CR25TPLT
CUT-OFF AND SIDELAY
REGISTER CONTROL

TECHNICAL FEATURES
• CR25TPLT longitudinal and sidelay register control system uses specially made
high-speed matrix video cameras, which make it possible to read register marks
(MicroMarks) in very small spaces (6 x 4 mm).
• Supplied separately or integrated with the CR25-CR26 color register control, this
system provides automatic control of the longitudinal and sidelay register of one or
more webs on folders, rotary cutters, perforators, etc.
• Multiprocessor units with DSP (Digital Signal Processing) Technology.
• Cameras can capture 200 images per second, and the marks are read on each
cylinder revolution.
• Speed of operation from 15 to 1500 m/min.

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 SOLUTIONS FOR WEB OFFSET

MOTORIZED BARS (OPTIONAL)

FOR THE AUTOMATIC
POSITIONING OF CAMERAS
ON THE MICROMARKS

• MicroMarks can be located anywhere on the printed web. They are not sensitive to
print conditions and can therefore always be identified by the cameras.
• Error sensitivity: 0.02 mm.
• Maximum correctable longitudinal and sidelay error ± 100 mm without operator’s
intervention.
• Correction of sidelay error with or without print.
• Completely automatic register mark search and lock on.
• Video cameras can be mounted on motorized bars presettable from the control
console, which enables automatic positioning on the marks.
• LED light sources with a lifetime of over 100,000 hours (11 years).
• When register errors exceed the preset value, an alarm and the waste ejector can
be activated automatically.
• The system is configured for remote support through a dedicated VPN connection.

CUT OFF MAIN OPERATOR SCREEN MOTORIZED CAMERAS SCREEN

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COLORSCAN
SPECTRO-DENSITOMETRIC
COLOR CONTROL SYSTEM

TECHNICAL FEATURES
• COLORSCAN is an automatic closed-loop color control using in-line spectrophoto-
metric and densitometric measurements.
• Fast and perfect color spectrophotometry/density control, along with a userfriendly
operation and a fully-automatic start-up ensure the best quality of the printed
product at any press speed (from 50 to 1000 m/min) and during the entire production.
• A specially made video camera allows measurement and control of CIE L*a*b*
values through the reading of images or a dedicated color bar with customer
specified dimensions.
• Precise and fast corrections on the ink keys are made comparing the measured
values and the values of a pre-press file.

MODULATING LIGHT WAVES

FOR A WIDE SPECTRAL
ANALYSIS OF COLOR

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 SOLUTIONS FOR WEB OFFSET

MEASURE
OF COLOR PARAMETERS
FOR 4 INK KEYS
SIMULTANEOUSLY

• LED light sources, with a lifetime of over 100,000 hours (11 years).
• Scanning field of 160 mm (4 ink keys) associated to high-speed camera
movement, guarantee reduced time for scanning the whole web.
• Elimination of manual measurements.
• Repeatability and maximum accuracy in measuring the densitometric values:
± 3% of average value.
• The chromatic parameters displayed in real time are:
- Optical density
- Dot Gain
- CIE L*a*b* values
- Chromatic balance
- Trapping
- Slur
- Print contrast
- Differences from set-point and real measured color “Δ ”
• Database containing all measured chromatic values with consequent availability
of quality reports up to single ink key details in any moment.
• Optical and/or acoustic signal when the dot gain exceeds the preset value.
• System COLORSCAN can manage data from pre-press, according to CIP3
standards, in order to preset inking profiles.
• The system is configured for remote support through a dedicated VPN
connection.

REAL TIME TRENDS DISPLAY MAIN CONTROL SCREEN

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PM3
PAPER MONITORING WEB SURFACE
ANALYSIS AND DEFECT INSPECTION

TECHNICAL FEATURES
• PM3 System continuously monitors paper from the reel stand up to the press
delivery. It allows the operator a quick means to distinguish the web breaks due to
the paper quality.
• For each roll, the system evaluates the average value of white paper in CIE L*a*b*
coordinates.
• High resolution color cameras detect the critical defects of white paper, supplying
information about the origin of breaks and paper quality with pictures and video
clips that can be taken in different areas of the press. As option, cameras on mobile
brackets can be supplied.
• Automatic loading of data relevant to the job and to the reel through connection to
either the company network or to a bar-code reader.

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 SOLUTIONS FOR WEB OFFSET

CAMERAS
ARE POSITIONED
AT CRITICAL POINTS
OF THE PRESS
(REEL STAND,
DRIER ENTRANCE,
SLITTERS)

ROLL MAPS DISPLAY

AND JOB STORAGE
CONSULTATION

• Information in real time.

• With a web break, the video clip is available immediately.
• The video clip in real time of a single camera or simultaneously of all connected
cameras (Multi View up to 12 cameras) can be displayed.
• For every detected defect, the system detects and stores the following information
by: - Type of defect
- Size and position of the defect in the reel
- Date and time of the paper break
- Color pictures
- Video clip associated to web break
• For every web break it is possible to print a report containing all information. Relevant
documentation, video clips and cartography of the reel with defect statistics and
white paper values in CIE L*a*b* coordinates are stored automatically.
• The system is configured for remote support through a dedicated VPN connection.

SELECTION OF INSPECTION CAMERAS WEB BREAK VIDEO CLIP ALLOWS EASY

AND REAL TIME VIDEO DISPLAY DISCRIMINATION OF THE CAUSE
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100% PRINT INSPECTION.
THE GUARANTEE FOR TOTAL
QUALITY CONTROL

LYNEX is a 100% print inspection developed by Grafikontrol to assure the total

quality control during the printing process. The continuous inspection of the entire
print repeat, with programmable sensitivities, allows the automatic detection
of all print or substrate defects and a real time evaluation of the production.
The immediate warning, when a flaw is detected, guarantees the elimination of
defective material which optimizes your process and avoids claims. The modular
architecture, combined with powerful hardware and dedicated algorithms for
image processing, make the LYNEX a flexible and easy to use instrument for
inspection on offset presses. LYNEX can operate as stand-alone module in
multiple processes.

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 SOLUTIONS FOR WEB OFFSET

SYSTEM CONFIGURATION
LYNEX combines one or more 4K-pixel RGB linear cameras for an accurate
real time inspection of the entire web width at production speeds exceeding
HIGH SPEED 1000 m/min. The information from the cameras is processed through powerful
hardware to provide accurate and reliable image inspection. Additional linear
LINEAR CAMERAS cameras can be dedicated to inspect the printed surface for the detection of
defects down to 0.01 mm.

LYNEX provides as standard the real time display of the entire print repeat.
REAL TIME Grafikontrol’s dedicated image processor displays the live image at EVERY
REPEAT as a full web viewer on a 32” or 55” UHD monitor. The operator can
FULL PRINT analyze the print conditions on the whole web and immediately intervene as
REPEAT DISPLAY needed. When a defect is detected the relative position is highlighted on the
screen.

DIGITAL ZOOM
ON IMAGE

“Easy and efficient” are the best terms to describe the new LYNEX operator
MODERN interface. Press operators will not struggle to learn how to use the system
functions, the gestures and actions are the same common ones used in
MULTITASKING smartphones and tablets. LYNEX is operated through a standard 23” HD 16:9
USER INTERFACE multitouch screen. Operators can navigate from screen to screen by just
touching or sliding the image.

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SYSTEM FUNCTIONS
• Digital Zoom: 6X digital zoom allows the operator to digitally zoom on certain details
over the entire print repeat by using the full print repeat monitor.
• Gallery of Defects: the chronological sequence of the defects and a scrolling function
provide easy evaluation of the process.
• Different Sensitivity Levels: the operator can define the sensitivity for each classification
of defect according to the job specification.
• Masking: undesired defects which cannot be removed from the printing, can be
completely masked to avoid constant alarms.
• Sensitivity by Zone: normally the system works with sensitivity levels set for the entire
print repeat, this special software allows the operator to select up to 24 zones (of various
sizes) which can have different sensitivities for each type of defect.
• Job Report & Statistics: for the total traceability of waste the system produces a defect
map for each printed roll showing in chronological order the defect, its coordinates and
a visual image for the reviewer.

DEFECT
ANALYSIS

• PDF/LIVE Master Comparison: this software, used during a job make-ready, allows an
easy and quick comparison of the live printing with the relative PDF pre-press file to
check for any differences. The in-line comparison is of big help when printing different
text languages or to detect faulty engravings. This function allows to detect errors of
plate engraving and plate positioning.
• ∆-Color Monitoring: through the live print repeat tab displayed on the multi-touch screen
the operator can easily select up to 24 points of measurement to monitor the color trend.
The ΔE values are continuously updated and visualized.

CAMERA
SINGLE VIEW

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SOLUTIONS FOR WEB OFFSET

TECHNICAL
D ATA

CR25-CR26
CR25TPLT
COLORSCAN
PM3

17
 TECHNICAL DATA

CR25-CR26 CR25TPLT COLORSCAN

Web offset printing, Web offset printing, Web offset printing,

APPLICATION AREAS Digital printing, Screen Digital printing, Screen Digital printing, Screen
printing, Folding carton printing, Folding carton printing, Folding carton

TYPE OF SUBSTRATE Paper Paper Paper

120-230V AC 50-60 Hz 120-230V AC 50-60 Hz 120-230V AC 50-60 Hz

POWER SUPPLY 1000VA 1000VA 1000VA

OPERATING +5/+40°C +5/+40°C +5/+40°C

TEMPERATURE

MEASURING
0.01 mm 0.01 mm 0.03 density points
RESOLUTION

ERROR ADJUSTMENT ± 2 mm Unlimited -

MAX CIRCUMFERENTIAL ± 1.6 mm ± 100 mm -

ERROR DEVIATION

MAX SIDELAY ± 7 mm (with fixed camera)

± 0.9 mm -
ERROR DEVIATION ± 30 mm (with motorized camera)

SIDELAY ERROR ± 2 mm (with fixed camera)

± 2 mm -
ADJUSTMENT Unlimited (with motorized camera)

OPERATING
15 - 1500 m/min 15 - 1500 m/min 50 - 1200 m/min
WEB SPEED

REPEATABILITY
AND MEASUREMENT - - 0.03%
ACCURACY

MAX WEB WIDTH - - -

WITH 1 CAMERA

DEFECT DETECTION - - -

CAMERA
640 x 480 640 x 480 2048 Linear camera
RESOLUTION

FRAME RATE / 200 fps 200 fps

70 KHz
LINE RATE Progressive scan CMOS Progressive scan CMOS

CAMERA
LVDS LVDS Camera LINK
INTERFACE

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 SOLUTIONS FOR WEB OFFSET

PM3

Gravure publication, Gravure, Flexo printing, Web offset

Web offset printing, Digital printing, APPLICATION AREAS printing, Digital printing,
Screen printing, Folding carton Screen printing, Folding carton

Paper TYPE OF SUBSTRATE Paper

120-230V AC 50-60 Hz SYSTEM PERFORMANCE

1000VA MAX WEB SPEED Up to 1000 m/min
MAX WEB WIDTH 4000 mm
+5/+40°C OPERATING TEMPERATURE 0/40°C

- ILLUMINATION UNIT TYPE Main illumination with dimmable

white LED, back side illumination,
lacquer flash, UV flash, embossing flash,
- hologram flash

USER INTERFACE
-
TYPE 23” TFT multi-touch screen
32” 4K - 55” 4K
RESOLUTION 1920 x 1080 pixel - 2560 x 1600 pixel -
- 3840 x 2160 pixel
SIGNAL INPUT DVI - display port - HDMI

-
SUPPLY VOLTAGE
POWER SUPPLY 115-230V AC 50-60 Hz - 1000 VA
10 - 1000 m/min
SENSOR TYPE RGB line scan camera, camera link 85MHz
B/W line scan camera - GigE
OPTICS Digital 6X zoom
-
NUMBER OF CAMERAS Up to 4 cameras
RESOLUTION 2048 pixel - 4096 pixel - 8192 pixel

2m
MAX IMAGE RESOLUTION 0.06 mm/pixel

MEASUREMENT VALUES
1 mm²
DATA EXPORT xml file

1296 x 996 HR camera

1600 x 1200 SHR camera INPUTS / OUTPUTS
FUNCTION INPUT Splice - inking
30 fps Progressive scan CCD HR camera OUTPUT FUNCTIONS/SIGNAL Sinoptic tower with acustic alarm,
55 fps Progressive scan CCD SHR camera waste/out of tolerance signal

Gigabit Ethernet (1000 Mbit/s)

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 SALES AGENCIES SALES AGENCIES
AND LOCAL SERVICE

WWW.GRAFIKONTROL.IT

ITALIA DEUTSCHLAND
W/O - rev.06.00.EN

GRAFIKONTROL SPA GRAFIKONTROL GMBH

Milano - Via Ludovico D’Aragona, 7 Maxdorf - Hauptstraße, 19
Ph. +39 02 2100951 Ph. +49 6237 925 95 61
[email protected] [email protected]