The use of plastic film is constantly expanding in traditional as well as in new applications. Quality demands for the raw material are rising to new standards while producers are seeking cost effective ways to improve the production process.

EVS optical inspection systems automate quality inspection in the production of plastic films (BOPP, PP, PET, etc.). The line speed and width along with the different production lines, determine the system configuration. High resolution image capturing enables detecting defects of 0.1-0.2 mm.


The Inspection Process

EVS optical inspection systems for the plastic film industry are designed to meet the quality needs of the end user at the plastic film production line. Speed of the line varies between 200m/min and 500m/min, with a typical minimum defect size of 0.1mm – 0.2mm.

The system hardware is designed to fit line structure constrains (space limitations), in almost all existing production lines. Typical film width ranges between 3m and 8m, with numerous cameras, especially in the upper width ranges.

Slit lines can be added prior to the inspection, when the width of each slit is known in advance and fixed. This will enable the operator to monitor defects per slit in the defects map, and also to issue a report per slit.

The typical inspection location is at the exit, just before the roll windings.

Detectable Defects:

• Orange skin
• Insect contamination
• Dirt contamination
• Crater
• Water spot
• Cold stretch spot
• Interface spot
• Temperature spot
• Snake skin
• Pick off
• Arrow end
• Scratches

Typical Defects

Orange skin	Water spot
Dirt contamination	Arrow end
Shiny spot	Snake skin
Cold stretch spot	Interface

System Benefits:

• Improved quality of final product
• Reduced labor costs
• Reduced running time and less repetitive defects
• Collecting defects data
• Central control on the line operation
• Increased automation of plant

System Highlights:

• Modular, compact, cost-effective
• Centralized control over multiple inspection points
• Inspection of images is performed inside smart cameras; central computer receives only inspection results
• No special knowledge of image processing is required for system operation or maintenance
• Operating System is based on Windows XP, with customized application programs
• Fast Ethernet communication
• Each camera is equipped with a Local Control Unit, capable of transmitting and receiving standard signals to or from external electronic devices

System Modules:

EIP - Embedded Image Processing integrates the video camera with the image processing hardware and software. With the implementation of EIP the system reliability is increased, the number of components is reduced, the installation process becomes significantly easier and the maintenance costs go down.

QST - Quick Style Tuning provides feedback from the video album review to the inspection instruction file. It enables rapid optimization of the inspection process of new styles, enhances the detection while minimizing over-detection.

DSA - Defect Sorting Algorithm enables better definition of defect categories for an automatic defect sorting into groups.


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