AI: The Game Changing Quality Control Tool in Print Production | SGK

Technology

AI: The Game Changing Quality Control Tool in Print Production

By Ingo Beutler & Dr. Daniel Schmidt

As a leading supplier of innovative tools and services for the packaging industry, Saueressig, part of the SGK family, has an acute understanding of the challenges that our clients and colleagues face daily. Quality control is a key area in which we, as an industry, strive for consistent innovation. We might be at the top of our game, but Saueressig is permanently working to do better and be better.

The challenge of quality control and print production

There is no room for error in print production. Print tools and print runs represent a significant expense for any client, and so the pressure to eliminate mistakes is immense. It’s essential that the tool matches design precisely to avoid the costs associated with re-running.

Until recently, this meant that a quality inspector would manually check printing tools – aiming to identify mismatches or damages. This time-consuming process is still common practice for some of our competitors, and – despite the skills of the professionals taking on the task – there is no guarantee of accuracy. QC is a crucial moment in the print production process and can make or break a printed packaging product. Our clients demand flawless results, and so this inexact process was ripe for overhaul when new technology came to the fore.

Exploding the potential of AI in print quality control

In the 2010s, while artificial intelligence was still just a buzzword, Saueressig identified an opportunity to use innovation to transform print plate inspections. cLynx was launched in 2016 as the first ever AI powered QC technology in print production. 

cLynx digitises the process of checking printing tools, completely removing the need for manual quality checking. The tool digitally analyses for micron mismatches, and can find thousands on a single file, each between 0.01mm and 0.05mm. It then builds up a digital model, rationalising the found errors for user friendliness. cLynx distinguishes any irrelevant faults – which could, for example, be dust – from the relevant ones. The end result: a QI is able to easily see true errors, making it quick and simple to identify necessary actions that will guarantee a flawless result.

Learning through use

cLynx learns by doing. Since its launch, we’ve overseen the process of building a catalogue of potential mismatches which have supported us to develop the software. We developed a scanner that takes an image directly from the print tool, not from the printed sample, and the AI tool learns what is different. 

cLynx products lead the international marketplace – thanks to the head start Saueressig claimed by harnessing AI at the earliest opportunity, and the extent of our experience and expertise in developing the AI to meet the needs of our clients.

The future of print production

This pace, with rapid improvements and utilisation of AI in print production quality inspection, continues to build. The benefits of the process are vast: inspection and handling costs are a minimum for customers, time is saved in production, internal improved workflow schedules dramatically increase productivity. The future of print production will undoubtedly incorporate developments in AI, and Saueressig will be at the forefront of this new era for print.

About Ingo Beutler

Ingo Beutler has been part of the print and media industry for more than 3 decades in various positions. After his first professional station as a media designer, he had the opportunity to share his experience in the print and media industry in leading positions at different companies. After being responsible for the entire prepress-business within the SAUERESSIG Group, Ingo Beutler is now in charge of digitisation at the SAUERESSIG Group. There he develops new applications for external and internal use with his team in order to create the entire process from design to printing more efficient and contemporary.

About Dr. Daniel Schmidt

Daniel Schmidt is a visionary leader in the field of computer vision and artificial intelligence, having embarked on his journey a decade ago with a groundbreaking student project aimed at enhancing the quality of rotogravure cylinders. His innovative approach not only revolutionized the production process but also significantly reduced costs, paving the way for substantial advancements in the industry. Since earning his PhD in Innovation and Economics, Daniel has successfully spearheaded numerous automation projects that have further propelled his company into the future of manufacturing. Daniel’s passion for innovation is matched only by his commitment to driving meaningful change, making him an invaluable asset to his team and the industry at large. His philosophy: “Innovation is not just about technology; it’s about transforming ideas into impactful realities.”

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