Cost Reducing Innovation in Registration Control for printing

1. CUSTOMER OPPORTUNITY
Lokmat Media Pvt Ltd – A multi platform media
company with interests in a diverse portfolio of
publishing, broadcast, media, entertainment,
community and sports verticals
Huge variation in registration at the winding
system at the time of pasting
Cost Reducing Innovation in Registration
Control
ACERCON
© 2019 Asaies Automation Pvt Ltd. All rights reserved.
SOLUTION RESULTS
Real time precision monitoring of color register
marks located in the printed web
High speed camera system for precision
monitoring
Reduced startup waste by 50% on press line
Reduction of wastage at the time of splicing
REGISTRATION CONTROL

2. Asaies Case Study Page 2
When printing an image that has more than one color, it is necessary to print each color
separately and ensure each color overlaps the others precisely. If this is not done, the finished
image will look fuzzy, blurred or out of register. Registration is affected due to lateral and
circumferential movement of paper which can be controlled by lateral and circum motors for each
color.
It is important to have quick registration especially during start-up and slicing to minimize waste
which is not possible with manual operations. It is also important to keep the perfect registration
consistently during the entire print run to ensure best print quality and maximum waste saving
LARGEST
READ READ MARATHI
NEWSPAPER
18 LAKH COPIES
CIRCULATION IN MAHARASHTRA
AND GOA
ABOUT THE CLIENT
Founded on 15 December, 1971, Lokmat Media is a multi platform
media company with interests in a diversified portfolio of publishing,
broadcast, digital, entertainment, community and sports verticals.
With Karan Darda, executive director, at the helm of affairs at Lokmat
Media, Lokmat is currently the largest read regional language Marathi
newspaper in Goa and Maharashtra states..
OPPORTUNITY
As a part of the plant expansion plan, 2C printing unit which acts as
an add-on in existing Hiline Y printing units for 4x4 printing was
mounted on the existing Manugraph Y units. As the number of colour
pages required in the newspapers is going up, the 2C units’ were
useful to print 4x4 colour inline.
Things were working fine, but Lokmat faced one peculiar problem with
the 2C units. At different speed and at the time of pasting, a huge
variation in registration was seen. The problem was more acute at the
winding system. Lokmat was looking for a concrete solution and even
at one point of time they felt that the system would not work with their
press
SOLUTION
Acercon is an innovative and proven color register control system by
ASAIES AUTOMATION for 4 color web offset printing machines.
Acercon system operates with real time precision monitoring of color
register marks located in the printed web. The high speed camera
system captures the images of printed register marks and processed
using a unique and high end image processing technology to find the
registration offsets and send control to motors for instant lateral and
circumferential corrections.
TOP 3 REASONS
Why Asaies’s ACERCON was
chosen as the solution against
competition?
1. Platform/Technology
A new generation and proven
Hardware and Software
Platform for excellent
performance.
2. Talented Team
expertise in Image
Processing & Machine Vision
applications, Embedded
Systems and Robotics
3. Turn-around time
Our turn-around time for
integration of latest
technology/ feature is much
less comparing to
competitors
© 2019 Asaies Automation Pvt Ltd. All rights reserved.

3. Asaies Case Study Page 3
RESULTS
The results were in line with the expectation and have
contributed in achieving consistent registration thus reducing
operational costs significantly. With the system they were able to
improve print quality, maximize waste saving and increase
returns. Continuing their efforts in investing in technology and
cost saving measures, Lokmat has also confirmed 4 more units
of ACERCON at their Nagpur and Nanded branches.
The solutions provided by similar software developers were
expensive and neither concrete, nor customized to our
requirements. ACERCON is a cost effective solution and
resulted in the reduction of wastage from 300-400 pages in
a single system at the time od splicing on the 2C unit to
almost zero!
“
NEERAJ MAHAJAN,
VICE PRESIDENT - TECHNICAL, LOKMAT MEDIA PVT LTD.
KEY FEATURES
v Circumferential and lateral color register control
v Quick response with concurrent motor controls
v Enhanced Touch UI for effortless operations
v Compensator Integration
v High Quality Camera and optics
v Proven proprietary controllers and software that is easily
customizable
v Compatible with most Coldset, Heatset and Flexo
presses
v Support windows, Linux and Mac platforms
v Low cost of ownership and maintenance
TECHNICAL SPECIFICATIONS
60%
REDUCTION
In Operational Costs
© 2019 Asaies Automation Pvt Ltd. All rights reserved.
SIGNIFICANT
IMPROVEMENT
In Print Quality
v SENSOR - HIGH SPEED CMOS SENSOR
v RESOLUTION - .01mm
v ILLUMINATING - MAINTENANCE-FREE LED-
FLASH-UNIT INTEGRATED INTO CAMERA
HOUSING
v MARK DIAMETER – 0.5mm to 2.0mm
v MEASURING ACCURACY - .01mm

4. ABOUT ACERCON
Acercon is an excellent register control system by ASAIES for multi color web offset presses (heatset and coldset) and also for
flexo printing. Acercon is built on true innovation and latest image processing technology to give unmatched performance,
print quality and economy to printers worldwide. Our high speed camera system and control unit with real-time data
processing enables faster response and instant registration thus minimizing the waste during startup and throughout the print
run. The system is highly user-friendly and efficient with rich GUI and touch interface with 100% hands free operations. The
product differentiates from other systems currently available with its unique approach and design to maximise waste saving
and achieve consistent register quality. The system provides printers with a predictable and outstanding return many times
over their investment by improving performance of presses.
ABOUT Asaies
We are a young Automation Company based in Kochi, India focused in providing industrial electronics and automation
solutions mainly for the Printing Industry. We consider automation as a tool to help people and businesses. We work on latest
image processing and embedded technologies to offer highly affordable and cost saving Press Automation Systems for the
printers across the World! Our products are mainly to help printers to save paper, ink, labour and time while improving print
quality and efficiency! Our customers could significantly reduce there printed waste and improve quality, there by improving
profitability! The company has expertise in Image Processing & Machine Vision applications, Embedded Systems and
Robotics etc and is driven by a team of highly talented and committed engineering and management professionals with many
years of industry experience.
Talk to us for Transformation through our Solutions
Asaies Case Study
| Kochi
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