100% inline inspection and comprehensive laboratory testing to ensure every label and package meets the highest standards of accuracy and performance.
SYSCON operates 100% inline inspection systems on every printing and converting line. High-resolution vision cameras scan each printed impression at full production speed, comparing it against a digital master reference. Any deviation -- whether a print defect, color shift, missing element, or registration error -- is instantly detected, flagged, and logged.
This means that every single label and every meter of flexible packaging film is inspected automatically before it leaves our facility. Defective material is identified and removed in real time, ensuring that only conforming product reaches our clients. Our inline systems achieve detection capabilities down to 0.1 mm, catching defects that are invisible to the human eye.
Barcodes are mission-critical elements on packaging -- a non-scannable barcode can result in product rejection at retail, supply chain disruption, and chargebacks. SYSCON employs dedicated inline barcode verification systems that grade every barcode according to ISO/IEC 15416 (linear) and ISO/IEC 15415 (2D) standards.
Our systems verify 1D barcodes (EAN, UPC, Code 128, ITF-14), 2D codes (QR codes, Data Matrix), and variable data elements such as sequential serial numbers, batch codes, and expiry dates. Each barcode is graded in real time, and any code that falls below the specified grade threshold triggers an automatic alert, ensuring 100% scannability of shipped product.
Beyond barcode verification, our vision systems perform comprehensive print defect detection across the entire printed surface. The system identifies and classifies a wide range of defects including ink splashes, hickeys, streaks, smearing, color variations, registration shifts, missing print elements, and foreign material contamination.
Each defect is categorized by type, severity, and location, generating detailed defect maps for every roll or batch produced. This data feeds into our quality management system, enabling trend analysis and root cause investigation. Press operators receive real-time visual alerts on monitor displays, allowing them to take immediate corrective action to minimize waste and maintain consistent quality throughout the run.
Maintaining consistent color throughout a production run is essential for brand integrity. SYSCON's inline spectrophotometric color monitoring systems continuously measure color values during printing, comparing them against the approved color standard in real time.
The system tracks Delta E values for process colors and spot colors, alerting operators instantly if color drifts outside the defined tolerance. This closed-loop approach to color control means that color consistency is maintained not just from impression to impression, but from roll to roll and from order to order -- ensuring that your brand colors remain faithful across every production batch.
SYSCON's in-house quality control laboratory conducts comprehensive physical and chemical testing on raw materials, in-process samples, and finished products. Our laboratory capabilities complement our inline inspection systems, providing the detailed analytical data needed to verify performance characteristics that cannot be assessed visually.
Our testing portfolio covers the critical performance properties that determine how packaging performs in real-world conditions -- from adhesion and seal integrity to migration safety and shelf-life stability. All testing is conducted according to recognized international standards (ASTM, ISO, EN) to ensure that results are reliable, reproducible, and accepted by our clients and regulatory bodies.
Technology and processes that ensure zero-defect delivery across every product line.
High-speed line-scan cameras providing 100% surface inspection on every printing and converting line.
Real-time SPC charting and trend analysis for critical quality parameters across all production runs.
In-house laboratory for adhesion, migration, seal strength, barrier, and mechanical property testing.
Detailed inspection reports, defect maps, and certificates of analysis provided with every shipment.
Our inspection and QC systems integrate with our printing and color management capabilities.
Spectrophotometric measurement and G7 calibration that provide the color standards our inspection systems verify.
Explore Color Management →Flexo, gravure, and digital presses equipped with integrated inspection and quality monitoring systems.
Explore Printing →ISO, BRC, GMP, and HACCP certifications that validate our quality management systems and processes.
View Certifications →Learn more about how SYSCON's inspection and quality control systems protect your brand and ensure consistent product quality.
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