Fujifilm’s Smart Monitoring Gate
Quality control is a constant focus, demanding ongoing attention, and where a slight registration drift or colour deviation can turn a profitable job into an unprofitable one.
Factors like temperature, humidity, and prolonged operation can lead to subtle variations in colour and paper alignment, all of which need minimising in a production run.
Our new ‘Smart Monitoring Gate’ monitors, measures, and corrects key quality parameters in real time, keeping print consistent, improving efficiency, and saving operator time.
The role of “smart monitoring”
The Smart Monitoring Gate is positioned externally to the toner printing unit, where the paper has cooled and stabilised to its natural state. This is deliberate, as paper can still be hot inside the press, resulting in expansion and distorted readings. By placing the module outside, measurements reflect the print’s true, final condition.
Two strategically placed scanners, one above and one below the sheet, continuously monitor both front-to-back registration and colour consistency. The system automatically prints four colour patches along the edges and cuts small crosses at the corners of each sheet. These marks give the sensors clear reference points for measuring registration and colour, and they do require a small margin, which might not be suitable for true edge-to-edge printing.
If a deviation is detected, the system instantly communicates with the press, making subtle adjustments to prevent errors before they occur. For short runs, this might not seem critical, as the press may finish before any variation creeps in. But on longer jobs, where temperature and humidity in the room can change over time, this system quietly keeps everything in line. That means fewer interventions, fewer errors, and far less risk of discovering problems too late
Smart adjustments without overcorrection
The module doesn’t react to every minor fluctuation. To avoid overcorrection, it calculates averages from the last ten printed sheets. For example, only when a deviation exceeds a preset threshold does it trigger an alert, either to inform the operator, or to pause the job, depending on the settings, but only ever triggering an alert when a drastic deviation occurs. This allows for smooth, gradual adjustments to ensure that the print quality remains stable and consistent without introducing unwanted fluctuations.
A closer look at the technology
The Smart Monitoring Gate handles a broad range of paper sizes, and can process stock from 52 to 400 gsm without breaking stride. All of this runs in the background, without interrupting production or slowing the press. And despite its capabilities, the module itself is compact and energy efficient. It’s engineered for high-volume environments, built to spot what the human eye might miss, and designed to do so without ever getting in the way.
Automation: more productivity and less waste
The Smart Monitoring Gate brings a significant boost to productivity by taking over a task that traditionally requires considerable operator time. Operators often spend around 3 minutes of each cycle manually checking the output. By automating this crucial quality control step, the Smart Monitoring Gate reduces manual checks and saves time, helping teams shift their focus from routine inspection to more valuable tasks, and improving overall productivity.
And because the system detects issues with registration and colour consistency early in the printing process, fewer sheets go to waste and less ink is used. The result is a simpler, more cost-effective and sustainable approach to printing. Importantly, the Smart Monitoring Gate performs its measurements and corrections on the fly so the print speed remains virtually unaffected.
Addressing concerns
It’s natural for customers to wonder: “If a correction system is needed, is the press really stable?” The answer is yes. The Revoria presses are designed for consistency. But environmental variables are real, and over long runs, they can add up.
This module is there as a proactive measure to maintain the highest quality standards, especially during longer runs, where any printing system could experience minor variations. It’s a tool that ensures consistent output and adds an extra layer of reassurance.
Looking ahead
The current module focuses on registration and colour but Fujifilm’s vision for print quality extends beyond this. A next-generation version, already available in Japan, introduces full-sheet inspection, capable of detecting wrinkles, spots, fibres, and other defects beyond the margins.
Fujifilm’s Smart Monitoring Gate is a valuable asset for any print provider seeking to optimise operations and deliver consistent high quality results. It minimises waste, maximises efficiency, and provides customers with the peace of mind that their prints will be perfect every time.
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