Plastic film, foil & sheets inspection

Defects in the production and converting of films used for flexible packaging or in converting stages can endanger the appearance and product safety. Holes, gels, contamination, coating, and laminating defects cause functional defects in the packaging. Contamination or other surface imperfections can affect the appearance of the packaging and reduce consumer confidence in the product.

The SMASH automatic quality inspection system reliably identifies all defects during production before they affect the appearance or lead to product safety issues.

During film production, the self-learning QuickTeach function automatically classifies defects and surface properties. In the cloud-based version of the feature, an AI-based cluster segments the defects autonomously and enables the processing of large amounts of data. 

With the help of an advanced lighting concept, every defect, regardless of its size, is detected in this production step and further classified based on each user’s requirements. Serious defects can be flagged or marked while all defects are classified and mapped. Haze can be monitored and the entire film surface is uniformly checked for homogeneity.

The operator easily splices defects out with the RewindManager function that stops the slitter or doctor machine at the location of critical defects for removal. Converting Optimization software allows a finished roll cut layout to segregate the defects and data for each finished slit roll that can be automatically graded as pass/fail based on that finished roll’s defect content.

Producing optical prism films, polarizer films, protective films, and window films requires extreme care and precision. The goal is to ensure the flawless quality of the products coated with them - from simple glass to complicated electronic circuits.  

During the production of optical films, critical defects can degrade polarization, reflectance, and transmission properties. These include harley bear defects, scratches pinholes, haze, coating, polarization defects, as well as oil spots, structural defects, and inhomogeneity.

The automatic SMASH surface inspection system detects even the smallest defects of optical films in real time. Line scan cameras ensure inspection at web speeds of approx. 10-100 m/min while maintaining the highest image resolution.

For optical film inspection, it is equipped with an automatic polarizer filter, which automatically adjusts the polarization angle. It sets the polarizer to full light extinction or to other predefined settings. As all settings and adaptations can be done online or automatically there is no need to stop the production for these adjustments. The lens also captures special defects like harley bear, which are not visible without such a filter. In addition, the inspection is complemented by advanced detection of scratches, another common, serious defect in optical films. 

Customized lighting supports the reliable detection and intelligent classification of defects that remain hidden from the human eye. As a result, conclusions can be drawn about causes or faulty process parameters, which can then be continuously monitored and optimized. 

PVB interlayers are an important component of safety glass used in various applications such as architectural glass, automotive windshields and head-up displays (HUD), and cruise ship glazing. Defective interlayers can lead to consequential delamination as well as discoloration in the laminated safety glass.

With state-of-the-art sensor technology and innovative software tools, the SMASH surface inspection system inspects PVB webs up to 3 meters wide on the fly. 

By equipping your extrusion line with state-of-the-art inspection technology, you offer your customers decisive advantages and secure a significant competitive edge for yourself. 

With our SurfaceSTAR product series, designed specifically for OEMs, we offer plug-and-play web inspection systems that integrate seamlessly into your extrusion lines. 

The SurfaceSTAR SIS (Surface Inspection System) includes high-quality embedded cameras and proven lighting technology that ensure maximum performance and reliability in defect detection. Advanced SMASH software and a user-friendly, browser-based Touch & Inspect graphical user interface further enhance the system's capabilities. With SurfaceSTAR SIS, your production system is capable of detecting defects as small as 150 µm, ensuring the highest level of quality control.

Our SurfaceSTAR GS (Gel Sensor) is a compact and efficient sensor unit designed to monitor gels and black spots during plastic film production. Direct communication between SurfaceSTAR GS and the PLC process control system creates a closed loop control system that immediately detects defects and forwards them to the process control system. This enables rapid response and regulation of temperature variations during extrusion. This prevents faulty production and leads to cost savings.

By integrating our vision solutions into your extrusion line, you can increase performance, efficiency and customer satisfaction. You'll offer your customers the benefits of smart, simple and excellent quality control - right from the start. In addition, our special OEM pricing gives you a cost advantage that increases the overall value proposition for your end customers.