The Smartphone Microscope allows control of minute details

Renowned for high-quality converting equipment for substrate processing, printing and converting, BOBST can look back on a long tradition of continuous improvement and modernization of a portfolio which covers all industries.

NOVAFOIL 106 - here the Hologram version with ACCUREGISTER
Top quality and greatest efficiency are the main theme for the latest innovations in the hot transfer stamping and die-cutting equipment. With NOVAFOIL 106 Hologram and the Digital Inspection Table for folding carton and flexible substrates, the BOBST equipment range has been enlarged with several innovations for high-precision and counterfeit-proof product converting.

Continuous innovation for maximum accuracy and efficiency
In 2021, BOBST introduced the NOVAFOIL 106, a hot transfer stamper for high-quality embellishment in folding carton production, responding to the continuing increase in demand for added-value finishing from brand owners. This compact machine features a significantly revised platen section, with longer dwell time, stable temperature and higher pressure for exceptional embellishment results, as well as an adapted gripper bar advance system, ensuring excellent running consistency and improved sheet deceleration. The optional cross-foil section gives converters greater flexibility and efficiency for producing complex embellishment layouts. Now tried and tested on customer’s production floors, the NOVAFOIL 106 has since proven it’s 24/7 production reliability.

Last year, the company increased the capabilities of the NOVAFOIL 106 even further by introducing a version which is dedicated to hologram applications - the NOVAFOIL 106 H. With up to 10 individual and completely redesigned modules, the transfer of holograms can now be done in an extremely efficient and flexible way, while still providing exceptional quality. Each hologram module is equipped with its own register and motor brakes for maximum accuracy and performance. Placed on either of two transversal rails, the modules can easily be slid into position and connected to the machine with a “plug-and-play” system.

The NOVAFOIL 106 is also available with ACCUREGISTER, the no-sheet-edge contact register which ensures 100% precision, and which was inspired by the BOBST POWER REGISTER. The ACCUREGISTER handles even shiny and transparent materials, correcting the sheet position in the front and lateral direction. It reduces feed-related machine stops and cuts down waste during machine setup, adding production and cost efficiency to the list of advantages.

“This machine has been conceived for converters who are specialized in top-end hologram application, such as banknote production” says Marco Lideo, Head of Product Line LADSF ETERNA at BOBST. “The NOVAFOIL 106 Hologram allows to be extremely efficient and precise. With 10 modules, even sophisticated designs are produced in one single run. Obviously, quality is paramount. That is why ACCUREGISTER guarantees the perfect positioning of the sheet, while the individual registers for the modules make sure the holograms are placed with greatest accuracy.”

New generation of digital tools
Enhancing precision and efficiency during setup, BOBST has also recently introduced the Digital Makeready Tool (DMT). It is used to position the transfer stamping tools on a honeycomb chase. By projecting the original and validated job pdf with the foil position directly on the chase, the tools can be fixed faster and more precisely, thereby significantly reducing setup time and waste. The same principle is applied to the unique offline quality control tool, the Digital Inspection Table (DIT). Projecting print, embellishment or die-cutting and creasing lines on a quality control sheet, any kind of divergence from the original pdf becomes immediately apparent.

The DIT is an amazingly flexible tool that offers a multitude of controls for specific purposes. The optical repeat length measurement can determine the distance between repeated features on a sheet and the included BOBST Crease Light offers operators a fast and consistent way to control pressure consistency across the entire sheet. With the unique BOBST Smartphone Microscope, even the tiniest details – such as micro-printing – can be made visible. It features top and side lights that are ideal for the inspection of various isotropic (e.g. print, gloss, emboss, UV) and anisotropic surfaces (e.g. holograms), often used in security features. As for the control of banknotes, back and front registration elements are easily checked thanks to the DIT backlight. The DIT can also be equipped with a spectrometer and UV light on request.

“The commercialization of a rapid 3D scan which is capable of measuring structural and tactile markers on surfaces down to microns, is imminent” says Marco Lideo, before adding: “Combined with the BOBST Smartphone Microscope, I am convinced that we are now able to check even the most sophisticated security measures, and we are ready for any banknote quality control challenges.”

With the Digital Inspection Table, quality control becomes faster, more precise, easily traceable, and considerably reduces makereadies and waste. Being able to verify even minute details, rely on data instead of human judgement, and produce detailed quality reports, gives converters and customers confidence in the final product.

Ultimately, great quality is not just one tool or perfect process. It is hundreds of different decisions made each day. Through its suite of connected digital tools, the DIT gives operators the information they need to make the right choices each time. Ultimately, by increasing the quality of decision making, converters improve their production performance, reduce waste, and are more profitable.

Combining modern technology with traditional know-how
Using digital data from the original pdf in the converting workflow, BOBST has made a huge step forward in the mastery of tooling setup and product quality control, while boosting productivity at the same time.

To put the icing on the cake, the DMT and DIT can also be connected to the BOBST Connect cloud-based platform or any existing ERP system, which enables the free flow of information between the tools and the back office. This means that the original job pdf from the graphic design office can be sent directly to the DMT and the DIT to setup and control the job. On the DIT, detailed quality control reports can be created and accessed through the cloud via a computer, a tablet or a smartphone, to ensure full traceability and continuous improvement through circular communication.

As Marco Lideo puts it: “Quality and security rely on precision and traceability. It is therefore essential to provide solutions which give converters the tools to ensure both. Using one and the same reference – the original job pdf – along the converting process is key to detect any potential errors along the way and guarantee an outstanding product which complies to the highest demands. By introducing new machine features and digital technologies, we want to satisfy those needs, while also pushing the boundaries of efficiency and productivity.”