Keeping an eye on quality - manroland sheetfed and REA JET realize sheet numbering

The printing press manufacturer manroland sheetfed therefore offers customized, needs-based retrofitting of machines in order to increase their flexibility. Together with REA JET, a sheet numbering system has now been implemented for an international packaging producer with the aim of automated quality control.

The so-called inline numbering was developed as optional equipment for a Roland 700 HiPrint and can be integrated into all models of the 700 series. manroland offers customers the individual adaptation of machines from a single source and, for the current project, brought REA JET on board as an experienced partner that has established itself on the market as a specialist for industrial coding and marking for more than 30 years. "Together with REA, we have found a solution that enables the customer to seamlessly trace production and thus further enhance the value of the printing press as an investment," says Dr. Holger Wiese, Head of Research at manroland, printing the constructive cooperation.

Sheet numbering in conjunction with the ROLAND InlineInspector 2.0 is an interesting alternative to the conventional solution where sheets are marked in batches using a strip inserter. With inline numbering, on the other hand, each individual sheet is marked with a permanent serial number for quality control purposes and can be traced at any time. In the event of deviations from the specified print pattern, the sheet in question can therefore be easily identified, separated and removed.

For this method, the thermal Inkjet Printer REA JET HR was integrated into the Roland 700. The sheets are separated directly at the feed table and then printed with a continuous number at the edge. The signaling for the high resolution, contact-free marking is done by laser sensor. The sheet feed via the digital input triggers printing for each individual sheet.

The InlineInspector 2.0 registers and logs possible problems, thus realizing continuous control and making the printing process transparent. Individual, faulty sheets can be located fast using the serial number generated by the REA JET HR and consistently removed. This reduces waste and lowers costs while increasing quality. Automation also increases productivity: 18,000 sheets can be processed per hour.

The impetus for the combination of sheet numbering and quality control came from a customer request. However, there is a lack of space on the production table, so the print heads have to be compact and flexibly positionable. After a test phase, the REA inkjet printer was finally successfully implemented together with the inspection system.

The compact REA JET HR was convincing across the board, as it was easy to integrate thanks to its slim design and numerous interfaces. In addition, there are no annoying hoses and the print head can be folded away if required. Thanks to HP technology, the system is maintenance-free, does not use solvent-based inks and solvents and is therefore also suitable for sensitive sectors such as the pharmaceutical and food industries. Manroland is also pleased with the short makeready time, the fast cartridge change, the good price/performance ratio and the economical ink consumption: 1.5 million sheets with a resolution of 150 dpi can be numbered with one cartridge.

The proximity to REA Elektronik also proved to be an advantage, as the company, like manroland, has its headquarters in Hesse. As a deadline had to be met, the installation was under time pressure. "REA was very flexible, we benefited from the short distance and REA was also convincing from a technical point of view," comments Dr. Wiese on the successful cooperation. In the future, REA will therefore also be the first choice for further retrofits and initial equipment as a listed inline coding and marking solution.

Manroland sheetfed GmbH, based in Offenbach am Main, is a leading international manufacturer of offset printing presses for commercial, packaging and publishing printing. Founded in Germany in 1871, the company is one of the most traditional printing press manufacturers and today has subsidiaries in more than 40 countries worldwide. Manroland Sheetfed GmbH is a wholly owned subsidiary of the privately owned British Langley Holdings plc, a global engineering conglomerate.

REA JET develops and produces marking and coding systems for industrial coding and marking. The portfolio includes Inkjet Printers, laser and marking systems, labeling solutions, inks and consumables. REA JET and the manufacturer of code verification systems REA VERIFIER are business units of REA Elektronik GmbH, based in Mühltal, near Frankfurt am Main. REA Elektronik was founded in 1982, is owner-managed and employs over 300 people (2014). All products are 100 percent made in Germany.