As digital printing continues to outpace traditional offset methods for short and mid-sized print runs, the demand for speed, precision, and error-free output is at an all-time high. Known for its flexibility and cost-efficiency, digital printing still faces a critical challenge: real-time quality assurance.
While many high-end digital printers include basic built-in sensors for monitoring color and alignment, these systems often fail to catch more subtle—and more costly—print defects like streaking, banding, or smudging. That’s where Chromasens, a specialist in industrial imaging, is stepping in with a powerful inspection solution built specifically for high-speed digital print environments.
Digital Printing’s Quality Gap
Unlike offset printing, which uses static plates and is typically inspected between runs, digital printing is dynamic and fast-paced—meaning defects can multiply rapidly if not caught instantly. Variable data printing, personalized content, and complex layouts only add to the challenge.
While color densitometers and spectrophotometers help maintain calibration, they can’t detect visual flaws caused by mechanical issues such as clogged inkjet nozzles or toner inconsistencies. To maintain high standards in real time, print providers need high-resolution image capture backed by powerful illumination and processing.
Chromasens’ High-Tech Answer to Printing Perfection
Chromasens has developed an integrated inspection system centered around its flagship allPIXA evo 15k DXGE color line scan camera. Designed specifically for fast digital print lines, the camera captures ultra-high-resolution RGB images with speeds of up to 49 kHz, using a 15k (15,360 pixels x 4 lines) Quadlinear CMOS sensor.
The allPIXA evo comes equipped with:
- Dual 10 GigE interfaces for high-speed data transmission
- Flexible trigger options for precise capture timing
- Support for Windows and Linux systems
- Compatibility with affordable 10 GigE network interface cards for improved cost efficiency
The camera is purpose-built for integration into fast, space-limited installations, making it ideal for high-throughput print environments where real-time error detection is critical to avoiding waste and costly reprints.
Illumination That Keeps Up With the Speed
To ensure consistent image quality during rapid scanning, Chromasens pairs its camera with the Corona II Bright Field illumination system. Capable of delivering up to 300,000 cd/m² in a compact 680 mm (2.23 ft) module, the lighting system compensates for reduced light collection at high speeds.
The Corona II uses water cooling to prevent thermal disruption near print heads and extends the lifespan of the LEDs. A patented reflector ensures uniform, intense illumination of the printed material, crucial for detecting fine visual defects.
Controlling the illumination is the Chromasens XLC4 LED Controller, which:
- Supplies up to 80 watts per channel
- Offers flash capability up to 60 kHz
- Monitors system temperature to ensure performance and durability
- Prevents brightness variation that could skew image data
Modular and Customizable
To support a wide range of printing applications, Chromasens offers modular accessories, including:
- Lens adapters
- Modular focusing units
- M95 camera extensions
- Compatible lenses, such as the APO-Rodagon 105/4.0
This adaptability ensures that the system can be customized for different press formats and production requirements—including web, flexographic, offset, and digital printing.
Driving the Future of Print Quality
Chromasens brings decades of machine vision expertise to an industry increasingly driven by automation, personalization, and on-demand output. By integrating high-resolution imaging with precision lighting and real-time control, the company’s inspection system reduces print errors, minimizes waste, and elevates overall production quality.
As print providers race to meet rising customer expectations with shorter runs and tighter margins, reliable inspection technology is becoming not just beneficial—but essential. With its line scan camera solution, Chromasens is helping printers catch defects before they become costly mistakes—ensuring every streak, smudge, or pixel drop is seen before it’s too late.
