TechnologyThe MGI AIS SmartScanner Intelligent Registration System
The MGI AIS SmartScanner Intelligent Registration System uses advanced computer programming techniques to create a breakthrough in print registration. The technology works to unify traditional and digital print processes including offset, lithography, flexography, toner, and inkjet technologies to optimize postpress finishing. As of September 2016, the AIS technology has been standard on all JETvarnish 3D digital enhancement presses and is available as an upgrade for prior installations.
Using iterative algorithms, the AIS processes individual sheet calculations at 5 billion functions per second. Adaptive inkjet head management controls and analytic image tools work together to create a new print file for each sheet (piece) run on an MGI digital enhancement press. The SmartScanner automatically adapts and adjusts the inkjet head to deposit varnish and foil for each sheet based on printed ink impressions and physical substrate characteristics. It is capable of correcting for hundreds of anchor reference points on each piece instead of the typical 2-3 points in traditional lead edge and side guide mechanisms. This functionality increases substrate compatibility with paper, plastics, synthetics, lamination, and metal stocks.
The AIS eliminates more than 80 percent of operator setup time spent on traditional registration processes, reducing makeready waste. Typical job setup time is between 1-3 minutes with properly calibrated installation and preloaded job files. It eliminates the need for registration marks and optimizes quality by treating each finished piece as a separate print job.
The AIS achieves variable data finishing (VDF) effects above that of traditional die-stamping and screen-UV processes--with up to 32 textures of embossed foil per piece, with varying heights up to 200 microns. To increase efficiency, the AIS can use an "Image Acquisition" function without a native print. It can register a job on the first sheet and then create a mirrored print file library for future embellishment applications. Each new job should benefit from improved accuracy from a growing reference library of computer data. Different jobs with different substrate stocks can be stacked together on the feeder and run continuously with no changeover time or loading effort if varnish and foil layer files are preloaded into the system. Users can then quickly provide customers new application versions, variations of 2D/3D dimensional textures, heights of embossing coverage, and foil enhancement options.