Digital SmartLine Workflow – the concept to process digital printed rolls
SMARTLINE PRESS
Smartline Sync Recorder
Generate Reel Syncfile
- Splice Management
- Inspection Syncronisation
- Waste Management
- Independent System
- No interface to planning
SMARTLINE QA
Smartline Sync Editor
Interface to QA System
- Open interface to QA System
- Independent inspection supported
- Integration of QS results
- Waste Management
SMARTLINE DOCTORING
SmartLine Doctoring
Waste Removal
- Automated Control
- Doctoring Control
- Modification of the SyncFile to control the corrugator
SMARTLINE CORRUGATOR
Smartline Corr
Order change management
- Corrugator Workflow
- Multilane Multijob
- Single sheet waste removal
- Maximum performance & reliability
- Ability to run analog print
Digitally produced print has a number of advantages compared to traditional printing processes. One of the most important benefits is the fact that it is now possible to produce short runs in a highly efficient way. To increase the efficiency even further, multiple different print jobs can be combined on a single roll. Jobs can be placed one after the other or different jobs next to each other or in a combination of both.
Converting processes occurring further downstream in the production process are often not prepared for the quick order change and require additional automated process control systems in order to be able to also participate in the advantages of digital print.
This task is handled by our DigiPrintWorkflow “SmartLine”. The system recognizes the following events reliably and accurately up to the maximum speed of the machine:
ORDER CHANGE - ROLL CHANGE
WASTE (START & END)
AREAS WITHOUT PRINT
SPLICE SECTIONS
Simple, reliable, robust and universally implemented
These events and the resulting actions are communicated via standardized interfaces to the production processes. DigiPrintWorkflow is available in different configurations.
Its completely independent principle of operation does not require any additional data from the production.
The system is simple, reliable, robust and can be used universally. The concept was developed for the general use with digital printing presses and can be implemented independently of equipment manufacturers.
Frame with paper run
Paper roll with SmartLine
Push button box and digital roll
Press Release
SmartLine helps GP's Hummingbird to become more agile
SmartLine helps GP's Hummingbird to become more agile
Georgia-Pacific’s West Chester sheet feeder facility recently completed the installation of the new SmartLine system from Erhardt+Leimer Corrugated. This corrugator upgrade enables GP’s West Chester operations to take full advantage of their Hummingbird business unit’s HP T1100S digital press, giving Georgia-Pacific a market-leading end-to-end capability.
SmartLine accurately and reliably synchronizes the corrugator’s setup changes to the changing print with no restriction on the minimum run lengths - 300 ft. setups have been run without issue, or the number of setup changes within a single roll of pre-print. SmartLine’s design does not require any special job-separator between different print jobs, thus reducing waste to the absolute minimum – as little as four feet.
The SmartLine embeds job information into the pre-print guiding line. This information is read at corrugator speeds of up to 1500 ft./min. on all paper types (brown, white, coated, flood varnished, etc.) and across all deckle variations without any adjustment. This encoding does not affect the existing line following equipment on the corrugator. When coupled with E+L’s Generation 5 TrimMaster, the guiding line’s width can be shrunk from the usual 5 mm to 3 mm, thus reducing the ink required by 40%, along with a corresponding reduction in trim waste.
“We integrated SmartLine into the GP Hummingbird workflow at West Chester. It allows GP Hummingbird to better automate the end-to-end process seamlessly for numerous short-runs and varying jobs across multiple print/corrugation lanes (deckles) per roll.” said Robert Seay, director - digital business ventures for GP Corrugated.
The SmartLine cameras can be positioned to either look up when running the printed roll at the double backer liner splicer, or down if the pre-print is run on the single facer liner. In both locations, paper path compensation is made due to the position of the wrap arms.
The SmartLine system gives un-rivalled reliability, unaffected by corrugating issues such as delamination and bridge breaks or any pre-corrugator roll editing. SmartLine is also able to remove print waste at the rotary shear or, where available, the cut-off knife’s waste removal system.
SmartLine is designed to be ‘stand-alone’: the basic system has no data interface, only a simple hardware interface with the corrugator, which requires no modification to the existing dry end control system. SmartLine can easily turn a corrugator into a digital corrugator – the simple push of a button when a roll is loaded is the only input required by an operator.
The premium system has various integration options to allow verification of the print read by the vision system with the corrugator’s schedule, roll manifest checking and production reporting. Measurement of the print’s “repeat length” provides valuable operator information to ensure that the “cut to mark” system is configured correctly.
A touch screen interface allows operators to monitor the system operation, and a detailed alarm system assists operators in identifying potential problems. Comprehensive remote support and diagnostic features enable E+L to provide rapid and effective technical assistance worldwide.
