According to PPL general manager (operations), Ashish Pradhan, PPL had been on the lookout for a top-of-the-line print defect detection system. Before finalizing on AVT, however, Mr. Pradhan studied other options.

"We looked at other inspection systems, [he] explains, "but we chose AVT's solution for a number of reasons. It is easy to use...; this was important as we wanted to ensure that the equipment be intensively used by press operators after it was installed. Secondly, the PrintVision 9000NT gives [operators the freedom] to focus on other issues with the comfort of knowing print quality is being monitored. Finally," Pradhan adds, "We like the flexibility tha enables us to change the sensitivity levels from job to job, depending on the print requirement: The pressman is still in charge."

The first PrintVision/9000NT system was installed on PPL's 8-color Nakajima gravure press. PrintVision AIS solutions check for spots, streaks, misprints, color variation, and register, and the parameters for each of these can be set independently and easily.

Once the first system had been installed and the operators learned how to set the optimum levels for their work, PPL noted a 50-percent reduction in customer complaints about print quality.

At this point, PPL looked at the options AVT offers for specialist packaging applications. So, when the second PrintVision/9000NT was installed on a 9-color 1.3 m web width Rotomec gravure press, it included the RiteSeal and Automatic Bar Code Verification (ABC) options.

[According to AVT], RiteSeal is an inspection solution for cold-seal adhesive application. A second camera is placed on the press to inspect the reverse side of the web and special lighting enables the cold seal to be seen and inspected for eveness of application and register. An image of the cold-seal application is displayed on the console and can be superimposed on the image of the printed side for visual checks and detailed examination of any faults.

ABC ensures that all bar codes are not only printed accurately, but guarantees readability and meets ANSI and CEN quality standards.

"The market trends in the packaging industry in India have changed drastically over the past five years," says Pradhan. "New and improved printing and packaging requires sophisticated production equipment."

He adds, "The customer is no longer willing to settle for anything but zero defects in terms of quality. At the same time, he is not willing to pay more for the product. This cost of quality is what the AVT systems address and not only enable us to meet the quality requirements, but meet them profitably," he concludes.

PPL's customers include international brands Nestle, Cadbury, Proctor and Gamble, Britannia, Pepsi, Lever Brothers, and others. Products are made from such substrates as PET (polyester) films, BOPP (biaxially oriented polypropylene), PVC (polyvinyl chloride), and shrink PVC with thicknesses of 10 microns and up.