Digital Converting Solutions

Digitalised production processes, smart machines and game-changing systems

You can view all entries in the category "Digital Converting Solutions" below.

RollScore - IoT quality control system for incoming rolls

ACA Systems Oy, Finland

RollScore is new IoT-solution that scores incoming rolls and defines if the roll is good or bad. The system has been developed by ACA Systems with 30 years expertise in the roll industry.

RollScore is based on:

1) High resolution hardness profile measured with a modern handheld device, ACA RoQ.
2) Operator's log on runnability.
3) Integrated cloud-based software combines information, compares historic data and forms a RollScore number from 1-100 which describes the quality of a roll.

How does it work?

1) Operator does a measurement
2) Data is automatically transferred to cloud service over Wi-Fi
3) RollScore is calculated and result is returned to the operator, a quality database is created for further analysis.

What are the main benefits of RollScore?

1) Realtime information about problematic rolls
2) Improved runnability and productivity
3) Possibility to rank roll suppliers

Data-Connected, Automated Colour Quality Workflow

BALDWIN Vision Systems, USA

Smart “Industry 4.0” connected platforms enable printers to communicate across workflows, utilize data for process improvement and standardisation, and reduce their dependency on the varying skill sets of a disappearing print workforce.

The colour quality workflow solution from BALDWIN Vision Systems automates the process of delivering absolute consistency from press-to-press, shift-to-shift, and plant-to-plant. Components include DeltaCam™ for inline (rather than sampled) spectral value measurement—in agreement with hand-held devices and ISO standards—ensuring that all printed products are within customers’ color specifications. ColorTrack™ is an intuitive “color expert in a box” software that facilitates fast, accurate press-side correction of ink formulations. Using InkWeigh™ software and scales, press operators can eliminate trial and error by weighing and tracking ink corrections at the press for each client, each job. Fully track ink inventories for creation of new recipes, manage leftovers, ensure full traceability, and optimize ink storage to greatly reduce waste and cost.

Comexi Cloud, data management to improve efficiency.

Comexi, Spain

In an increasingly competitive market, where traditional technologies are getting to a consolidated point of maturity, processes and services are becoming increasingly relevant in today’s industrial world.

Optimising processes, reducing both, waste resources and time to market and getting product traceability, are some of the main goals that converters need to cope with everyday.

Machines are currently creating and managing a huge amount of data, some of which are even interconnected with other types of machines or services. The management and analysis of all this data is being used for many companies to build up new processes, to increase the competitiveness and to create new associated services. Furthemore, by considering the need of interconnecting machines and systems to get a holistic view of the business, we find ourselves in front of a new industrial paradigm, the industry 4.0. An industry that definetely is the cradle of Comexi Cloud development.

Analytics platform TEOC - the end of coincidences

DIENES Werke für Maschinenteile GmbH & Co. KG, Germany

TEOC is an analysis platform for digitally optimising slitting processes. Data of slitting systems is collected and analysed. This allows for predictive forecasts, reduces machine downtimes and increases productivity. Coincidence comes to an end.

TEOC offers customers tailor-made analyses to increase knife running performance. Limit values/average values are displayed, notifications sent, associations aggregated and forecasts made.
The use of the platform is independent of the location of the slitting machines. Communication between the systems and TEOC is based on current, standardised and encrypted protocols. On request, TEOC can be offered locally with an optimised scope of services.

In detail, the customer achieves lower production costs, higher product quality and increased slitting know-how with TEOC. TEOC offers support throughout the entire operation; helps machine operators operate the machine and production planners utilise the capacity of the plant, offers predictive maintenance and facilitates procurement for buyers.

TEOC increases customer's competitiveness.

ICAD® Technology - for Inline Continuous Automated Dynamic UV Monitoring


EFSEN's proprietary ICAD® technology is the first ever technology that enables measuring and control of the actual UV output that reaches the product - even during production.

ICAD® ensures that the UV is performing according to the set specifications and is documented - at all times.
ICAD® enables constant surveillance of the full width of the UV or UV-LED system, inline and without disrupting production.
When coupled with a UV LED system like P-LED, ICAD® generates a uniform UV output - forever.
Using ICAD® on conventional UV-systems enables manufactures to guarantee a certain UV dose at any point of the production width.
ICAD® enables correct and planned maintenance of UV and utilises UV-bulbs and UV-LEDs to their full potential.
ICAD® discloses everything about the UV status in production.

RFID winding cores for automated and integrated logistic processes

INOMETA GmbH, Germany

Inometa offers the world's first reusable winding cores made of metal, with an integrated RFID tag. They will efficiently support automated and integrated logistic processes. The outstanding advantages of the WinCore® system are its high rigidity and low wear. These qualities combined with RFID technology create tremendous cost benefits along the entire value chain.

In cooperation with the strategic partner Schoeller Supply Chain Technologies, a specialist for RFID-supported goods supply chains, INOMETA has developed an integrated solution for challenging production and logistics processes, with the RFID winding cores.

With the RFID tag, the material flow can be organised continuously, securely and in real time. The unloading and loading times upon the receipt and dispatch of goods are reduced significantly, since the inbound and outbound acquisition of goods is performed automatically in a fail-safe and faultless manner.

VacuFL3X – 3D-printed, temperature-controlled vacuum-roller-construction-kit with stationary and variable vacuum-zone

JHT Jakobs-Houben Technologie GmbH, Germany

3D-Printing revolutionises roll-manufacturing and R2R-processing. The vacuum-roller-system "VacuFL3X" represents an additively manufactured modular system. Special features are the integrated, independently controllable vacuum-lines. The actuation takes place via a frontally contacting, stationary sealing-system, which specifies the wrap angle. This can be varied by a tool-free exchangeable system. The contacting vacuum-zones are adapted substrate-optimised. They are interconnected symmetrically to the web-center. The independently controlled pipe-structures allow on and off switching of the vacuum-zones. As a result, different web-widths can be handled energy efficiently. The fluidly merging and changing cable-cross-sections are aerodynamically optimised. This allows an evenly and targeted vacuum-buildup over the web-width. The co-rotating vacuum lines are topology-optimised. In addition to resource-saving use of materials, the rigidity results are ≈20% higher. Active-assisted, air-driven separation-zones and optimised vacuum-zone-geometries facilitate the detachment and gentle handling of sensitive materials. Furthermore, they enable contactless web deflection. Besides that, the roller is equipped with a temperature-controlled shell.

Maximum transparency in the emergency stop circuit with self-test and diagnostic programme

Neo System Tec GmbH, Germany

The Emergency Stop Inspector 4.0 is an emergency stop control according to the new Machinery Directive. It achieves the highest safety requirements SIL3/Kat.4/PLe. Both, Stop Category 1 and Stop Category 2 can be implemented.
The triggered switches can be precisely located , thus minimising service calls and machine down times. In the spirit of Industry 4.0, the emergency-stop switch is transformed from a signal transmitter to a data source.
With the self-test and diagnostic programme E-Stop Inspector, the prescribed emergency stop maintenance intervals can be carried out software-based. The emergency-stop test is started and observed by the use of the visualisation. The emergency-stop switches are triggered, the switches and the hardware are diagnosed by the programme and the result of the test is displayed. The results can then be saved as a PDF file, printed out, and added to the plant documentation.

Predictive Production plastPMS

R.A.M. Realtime Application Measurement GmbH, Germany

In the light of Industry 4.0, R.A.M. GmbH interlinks machines and sensors in the "plastPMS" system. The user gets access to all production parameters and can intervene directly in the process. The correlation of previously independent data offers completely new ways of quality optimisation.
The "plastPMS" system offers everything at a glance. Sophisticated mathematical algorithms help map the process virtually (Big Data), optimise it and reapply it.

- Higher effectiveness of all systems
- Waste reduction / plastic waste reduction
- Optimal use of resources
- Improved machine utilisation
- Quality improvement
- Increase in production
- Minimisation / reduction of the use of plastics

Sophisticated data mining algorithms identify patterns in big data and thus acquire completely new insights and coherences. Thus, mistakes are corrected before they appear.

plastPMS = plastic production monitoring system

Successfully digitise service processes with Remote Maintenance

TECUMA Systems GmbH, Germany

In addition to the maintenance of the systems, time-consuming and costly service processes follow when complex faults or incorrect settings occur. As part of a project for an international client from Norway, the machinery used there has been equipped with a new digital service concept.
The Smart Service solution "Remote Maintenance Assistance” enables cooperation of the machine operator on site with the remote expert through a multimedia interaction in real time, based on a collaborative platform. Combined with the HMT-1 head-mounted tablet, supporting expertise is provided remotely to the machine operator. Thus, the on-site technician is able to continue working on the machine with both hands.

Avoiding the expensive dispatch of service technicians, the faster and even more direct support of the customer's machine operators, the operator's ability to work on the machine with both hands, and the simultaneous visualisation of information on the display are only some of the many benefits.

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