BBS Intelligent Quality Online Control Systems DPI1040

BBS online inspection system for automatic quality control of 100% of production on sheet-fed offset presses. The DPI1040 detects printing defects, ink spots, missing areas, damaged paper, and color anomalies in real time, operating at speeds of up to 18,000 sheets per hour with a maximum format of 1040 × 720 mm.

The BBS DPI1040 is an artificial vision system installed directly on a sheet-fed offset printing press to inspect the quality of every printed sheet in real time.

The system uses high-speed industrial line-scan cameras, LED lighting, and deep-learning-based analysis algorithms to automatically detect printing defects, substrate anomalies, and variations from the approved reference sample.

With a declared maximum speed of 18,000 sheets per hour, the DPI1040 helps identify consecutive waste and serious defects at an early stage, reducing material loss and easing the operator’s inspection workload. It can also record images, production data, and quality statistics, with optional MES or ERP integration.

Real-Time Quality Inspection

Every sheet is captured and analyzed during production. The software compares the acquired image with the approved reference template and immediately reports any anomaly.

First-Sheet Inspection

The system includes an online first-sample inspection function, allowing the operator to confirm that the job is correct before full production begins.

Intelligent Defect Classification

The analysis algorithms can distinguish isolated defects, consecutive waste, and serious anomalies, helping reduce false alarms and allowing the operator to respond more quickly.

Simplified Job Modelling

The inspection model is created through a guided interface where the operator can set parameters, thresholds, and areas of interest.

Data Recording and Traceability

The system can store:

• images of inspected sheets;
• defect images;
• production quantities;
• good product percentage;
• waste percentage;
• system operating status;
• inspection parameters;
• inspection results.

The data can be reviewed, shared through a network, and exported for further quality analysis.

Detectable Defects

The BBS DPI1040 can identify:

• missing print;
• ink spots;
• dirty print;
• torn paper;
• ink leakage or splashes;
• dry plate;
• plate smearing or filling;
• double image;
• incorrect plate;
• point defects;
• linear defects;
• weak or light printing;
• consecutive defects;
• serious production anomalies.

System Configuration

The indicative configuration includes:

• 8K industrial color line-scan cameras;
• industrial lenses;
• LED light source;
• image acquisition cards;
• dedicated image processing cards;
• industrial computer;
• synchronization module with encoder;
• large display monitor;
• pneumatic sheet-flattening system;
• camera mounting structure;
• electrical control cabinet;
• inspection and analysis software.

The system uses cameras, high-speed acquisition hardware, an encoder, lighting, computing units, and image processing to synchronize inspection with the actual speed of the printing press.

Lighting System

The light source is a key component in ensuring stable and uniform image acquisition. The standard configuration uses a high-intensity white linear LED light source designed to provide:

• high brightness;
• uniform illumination across the inspection width;
• long operating life;
• easy maintenance;
• forced-air cooling.

Waste Marking System

Depending on the selected configuration, defective sheets can be identified by:

• automatic label insertion;
• spray marking;
• pneumatic marking device;
• defect position indication for the operator.

The marking device is installed in the delivery or collection section of the press, making it easier to locate defective sheets during subsequent processing.

Installation on the Printing Press

The system is designed to be integrated into the sheet-fed offset press while minimizing structural modifications.

The cameras are positioned near the printing or transfer cylinder, while the lighting and air ducts are installed below the inspection area.

Synchronization is achieved through an encoder so that the image acquisition frequency follows the actual sheet speed and prevents longitudinal image distortion.

For materials heavier than 350 g/m², a high-pressure air supply or dedicated compressor may be required.

Customer Benefits

• Automatic inspection of 100% of printed sheets.
• Reduced consecutive waste.
• Immediate identification of serious defects.
• Less dependence on manual visual inspection.
• Lower costs related to reprints and customer claims.
• Consistent inspection even at high production speeds.
• Complete production traceability.
• Historical review of defect images.
• MES and ERP integration capability.
• Automatic marking of non-conforming sheets.
• Greater process stability and standardization.

Recommended Applications

The BBS DPI1040 is suitable for:

• publishing print production;
• commercial printing;
• packaging and folding cartons;
• pharmaceutical print products;
• labels and paperboard products;
• manuals and technical documentation;
• high-quality print jobs;
• productions requiring inspection of every individual sheet