Our camera-based inspection system for perfect binders, gathering machines, and saddle stitchers is a prime example of how you can significantly boost the performance of existing equipment with a modest investment. Retrofitting with our PPL camera system pays off noticeably in terms of efficiency, quality, and resource-efficient production.
"PPL Eagle" camera system for perfect binders or saddle stitchers
Seamlessly monitor the correct signature sequence
The key argument for using our PPL camera system is the ability to seamlessly verify the correct signature sequence on perfect binders and saddle stitchers. This ensures that no signatures are lost or swapped during the production process and prevents mix-ups when processing different language versions.
Higher quality, lower complaint rate: The benefits of a camera system
Verifying the correct sheet sequence is just one of many benefits offered by our retrofittable camera systems for print finishing.
- Quality assurance: Switching from random sampling to systematic, continuous checks simplifies quality management and strengthens your position when dealing with existing and new customers.
- Certification: The barcode recognition capabilities of our solution are a key component of all relevant audits, assisting you with preparation and documentation.
- Waste reduction: Early error detection helps conserve raw materials—specifically printed paper—and ensures cost-efficient production.
- Low complaint rate: You boost customer satisfaction and reduce the risk of jeopardizing hard-won business relationships due to defective products.
Configuration: One camera per feeder
We equip each feeder on a saddle stitcher—or each station on a gathering machine—with a camera that recognizes images and barcodes, capturing the sheet immediately after it leaves the feeder. The camera is installed downstream of the feeder or station, in the direction of sheet travel.
During operation, the cameras can be selected individually and adapted to each specific job. Mixed-mode operation—combining image and barcode recognition—is also possible. Camera parameters are configured to ensure trouble-free production while reliably detecting incorrect sheets.
Monitoring and Log Files: Nothing Gets Lost
All data relevant to the job is automatically captured and recorded in a log file.
Once the job is complete, the corresponding log files are automatically made available to your customer, who can use them as evidence during audits or in the event of a complaint. You can read the details of exactly how this works and what data the log files contain in our blog post on the subject.
One system, two operating modes: image recognition and barcode recognition
The image recognition ensures a high level of security with the optical comparison. The simple operation is additionally supported by an automated learning algorithm that takes parameters such as exposure time, contrast and position into account. Barcode recognition ensures error-free allocation of folded sheets by decoding and further processing the information stored in the barcode.
Compatibility
Our camera system can be combined with the following machines:
- Saddle stitchers
- Heidelberg Stitchmaster ST 500
- Heidelberg Stitchmaster ST 450
- Heidelberg Stitchmaster ST 400
- Heidelberg Stitchmaster ST 350
- Heidelberg Stitchmaster ST 300
- Saddle stitchers from other manufacturers: e.g., Müller Martini Presto E90, Kolbus ZTM, Hohner saddle stitchers, Horizon ZTM
- Perfect binding lines with gathering machines
- Smyth sewing lines with gathering machines
- Other machines upon request
You can read how the system works using the example of a Heidelberg saddle stitcher ST450 in the October 2020 issue of the trade magazine Bindereport. In addition to the advantages mentioned above, the solution also has other impressive features:
- no additional setup times,
- a separate control communicates with the control of the existing system: the machine stops if sheets are inserted incorrectly or ejects them via a missing sheet delivery,
- automatic creation of log files in the background,
- Remote connection of the system to a technical hotline.
Would you like to use these advantages for your company and retrofit your existing system with a PPL Eagle camera system instead of buying a new one? We would be happy to advise you on the options for your saddle stitcher, perfect binding line or thread stitching line.
Do you have a question about the system or would you like further information?
You can use our inquiry form to conveniently and directly send us questions about the camera and barcode system or request more detailed information. We will get back to you as soon as possible.