Cincinnati, Ohio based Valco Melton, a global leader in adhesive application and quality inspection systems for the corrugated industry, has announced the launch of DieCutChek, a real-time vision inspection system designed specifically for die-cutters and flexo-folder-gluers.
The new system extends Valco Melton’s proven ClearVision technology upstream in the production process, enabling corrugated manufacturers to detect quality defects at the die-cutting stage.
DieCutChek automatically inspects every die-cut sheet in real-time at speeds up to 300m/min (980ft/min). The system verifies final sheet dimensions, inspects die-cut shapes for missing or partial cuts, detects loose scrap on sheets, and measures sheet rotation. With 0.5mm resolution, DieCutChek can identify defects as small as 3.0mm in diameter.
The system uses multiple high-resolution line-scan cameras with integrated LED lighting mounted over the stacker conveyor. Advanced algorithms analyze each sheet as it passes through the inspection zone, comparing measurements against job specifications.Defects are instantly flagged on the intuitive ClearVision touchscreen interface, enabling them to be removed from the production stream and aiding in troubleshooting.
DieCutChek features real-time sheet size Statistical Process Control (SPC) monitoring that continuously tracks dimensional process data and calculates Cp and Cpk values. Automated trend-based alarming alerts operators to process drift before defects occur, while email escalation notifies management of quality issues requiring attention.
All inspection data is stored for complete traceability, supporting quality reporting and analysis. DieCutChek data can be monitored through MeasurementChek and MySystemChek for comprehensive production visibility.
By identifying defects at the die-cutting stage, DieCutChek enables operators to make immediate process adjustments, preventing the production of out-of-spec sheets and reducing waste. Optional integration with UV marking and bundle ejection systems enables automated removal of defective sheets from the production stream.
DieCutChek gives corrugated manufacturers the confidence that only quality sheets are leaving their facility, protecting customer relationships and reducing costly returns. DieCutChek is available now through Valco Melton’s global network of representatives.
