FUTEC EasyMax.MC inspects the printed web surface in-line or off-line with the use of CCD-based cameras while the web is running at high speed. When defects are detected, the system automatically activates a warning light and horn unit, displaying/storing flaw information together with images, and outputs various real-time or delayed signals for down stream control.

EasyMax.MC Applicable Lines: Gravure, Web Offset, Flexographic Printing Machines, Laminator Machines, Slitter Machines , Re-winder Machines

EasyMax.MC Defect types: Doctor Blade and other streaks, Scumming, Ink Splashes, Print Smear, Foreign Matters, Ink Void, missing parts of letters and many other defects.

• 100% web inspection 100% of the time; no operator input needed
• Automatically detects contamination and surface imperfections using high speed cameras
• Flaw video system - records defect images and stores them for later analysis
• Sorts defects into categories and displays a histogram enabling quick analysis and correction of the most common defects
• Networking - All EASYMAX.MC systems can be connected via standard LAN (local area networks) to the customer’s PC network. This enables all flaw information to be extracted for analysis away from the press
• Stable sensitivity even at high process speeds
• Store system settings by job number making set-up fast and easy
• Defect is clearly shown on screen with x-y co-ordinates to allow easy location; multiple defects can be displayed at a single time
• Optional Labeler applies a tag to the web’s edge so the defect can be easily found in the finished roll
• Zoning - can divide inspection width up to 16 zones (lanes)
• Hardcopy - print-out shows distribution defects at a glance.

• Continuous, pro-active inspection - 100% of the web, 100% of the time
• Consistent quality of inspection guaranteed, regardless of operator experience or shift changes
• Increases productivity by optimizing press speed and quality levels
• Provides early warning of impending faults
• Improves company image and competitive advantage
• Identifies random and continuous flaws and can even show that apparently random flaws are repeated
• Displays flaws on screen in color for rapid identification of the nature and source of the fault
• Can be used towards ISO 9000 accreditation
• Reduces contractual penalties
• Maximizes production yield from expensive materials and reduces need for production over-runs
• Minimizes waste of expensive materials, processing costs and embarrassing and expensive customer returns
• Makes short production runs easy and more cost effective
• Can help to maximize utilization of existing machinery
• Frees up operators for other tasks

There are two lighting methods used for detection of defects: Reflection or Transmission. The standard lighting system, diffuse reflection, works with all opaque materials such as papers, carton laminates and foils. The transmission lighting system, placed under the web, works with translucent materials such as films. A combination of both can be used.

• Signal processing unit
• Camera
• Lighting unit with ballast box
• Rotary encoder
• Beacon light with horn
• Cables, PC & Printer
• Color flaw video system

• Labeler
• Light control switch
• Transmission light box
• Separate flaw monitor
• Remote LED

Easy Setup
Inspection width, repeat length, and other parameters are set visually. It is no longer necessary to take physical measurements of the web as with conventional systems. This shortens the setup time.

Easy Keypad
Dedicated easy keypad helps set up the system quickly and easily.

Master Parameters
Three different levels of master settings are pre-installed. This facilitates setup of parameters of new product codes. No need to start from scratch.

Flaw Image Display
The top screen capture to the right shows the main operator screen with the defect image itself. The defect areas are centered and highlighted by flashing areas of color corresponding to the position of the defects. This makes it easier to identify low contrast defects. Using Futec’s latest digital video techniques the flaw image is captured and displayed to a quality never seen before from line scan technology. There are also zoom facilities to show defective areas full screen. The small images to the bottom left show any additional defects captured at the same time as the main one.

Flaw Map
The right hand side of the screen shows a flaw map indicating pictorially where defects are occurring in relation to meters into a roll and across the web width. This helps operators determine the frequency and location of defects and which output streams are affected so that counter measures can be taken as necessary. The flaw map is also used as a rapid selection of previous defects in the job for review purposes.

Flaw Sorting (Multiple image display)
The high-speed nature of EasyMax.MC means that it is capable of capturing flaw information at an unprecedented rate. It is essential that operators can sort critical defects from acceptable ones for rapid and effective decision-making. The multiple image display enables rapid sorting of defect images into the serious, large, medium and small categories. This screen also makes it easy to set alarm and waste output levels on the basis of the results being obtained. In this way, quality control and analysis on defect causes are achieved without sacrificing the yield ratio.

Historical Data (bottom screen capture)
Defect data, together with images is automatically stored in the past data file by job, and batch within the job. The system maintains a buffer of two million defect images. This enables operators to review and analyses defects in historical jobs.